System and method for converting material comprising bitumen into light hydrocarbon liquid product

ABSTRACT

Various methods and systems for obtaining light hydrocarbon distillate from material comprising bitumen are disclosed. The method may include a primary leaching or extraction process that separates most of the bitumen from the material comprising bitumen and results in a bitumen-enriched solvent phase and first solvent-wet tailings. The bitumen-enriched solvent phase includes mainly solvent and bitumen. The bitumen-enriched solvent phase is injected into a nozzle reactor wherein at least a portion of the bitumen is cracked into light hydrocarbon distillate. The light hydrocarbon distillate may then be used as solvent in the first primary leaching or extraction step.

BACKGROUND

Bitumen is an extremely heavy type of crude oil that is often found innaturally occurring geological materials such as tar sands, blackshales, coal formations, and weathered hydrocarbon sources contained insandstones and carbonates. Bitumen may be described as flammable brownor black mixtures or tar-like hydrocarbons derived naturally or bydistillation from petroleum. Bitumen can be in the form of a viscous oilto a brittle solid, including asphalt, tars, and natural mineral waxes.Substances containing bitumen may be referred to as bituminous, e.g.,bituminous coal, bituminous tar, or bituminous pitch. At roomtemperature, the flowability of bitumen is much like cold molasses.Bitumen may be processed to yield oil and other commercially usefulproducts, primarily by cracking the bitumen into lighter hydrocarbonmaterial. A comparison between the properties of Athabasca-type bitumenand an average crude oil is presented in the following table.

Property (typical) Bitumen Crude Oil Specific gravity - g/cc 1.05 0.85Viscosity @ 38 deg C. - cp 750,000 <200 Carbon - % 83 86 Hydrogen - %10.5 13.5 H/C mol ratio 1.5 1.9 Sulfur 5.0 <0.5 C5 asphaltenes - % 17 <5Resins - % 34 <20 Aromatics - % 34 >30 Saturates - % 15 >35 Conradsoncarbon - % 15 <5

As noted above, tar sands represent one of the well known sources ofbitumen. Tar sands typically include bitumen, water and mineral solids.The mineral solids can include inorganic solids such as coal, sand, andclay. Tar sand deposits can be found in many parts of the world,including North America. One of the largest tar sands deposits is in theAthabasca region of Alberta, Canada. In the Athabasca region, the tarsands formation can be found at the surface, although it may be buriedas deep as two thousand feet below the surface overburden. Tar sandsdeposits are measured in barrels equivalent of oil. It is estimated thatthe Athabasca tar sands deposit contains the equivalent of about 1.7 to2.3 trillion barrels of oil. Global tar sands deposits have beenestimated to contain up to 4 trillion barrels of oil. By way ofcomparison, the proven worldwide oil reserves are estimated to be about1.3 trillion barrels.

The bitumen content of tar sands varies from approximately 3 wt % to 21wt %, with a typical content of approximately 12 wt %. As such, aninitial step in deriving oil and other commercially useful products frombitumen typically requires extracting the bitumen from the naturallyoccurring geological material. In the case of tar sands, this mayinclude separating the bitumen from the mineral solids and othercomponents of tar sands.

One conventional process includes mixing the tar sands ore with hotwater to form a bitumen enriched froth. The froth is separated andfurther processed to isolate the bitumen product. Conventionalwater-based extraction technologies are capable of separating bitumenfrom higher grade ore but are unable to economically separate bitumenfrom lower grade ore. Unfortunately, this means that a significantamount of tar sand ore is not capable of being processed to recover theotherwise valuable bitumen.

Another problem with conventional water based extraction technologies isthe low overall recovery rate of bitumen. Unfortunately, someconventional extraction processes discharge part of the bitumen in theore with the tailings. Other conventional processes discharge asignificant part of the bitumen in the ore as an asphaltene precipitatewith the tailings. Not only does this reduce the efficiency of theextraction process due to lower recoveries, but it also presentspotential environmental problems that must be addressed.

Many conventional methods for obtaining bitumen from tar sands also haveserious technical limitations. For example, many conventional methodsuse water, which can cause clays in the tar sands to swell and interferewith processing equipment. In addition, some conventional methods resultin the undesirable precipitation of soluble asphaltenes.

One example of a conventional method is described in U.S. Pat. No.4,046,668 (the '668 patent). The '668 patent discloses the extraction ofhydrocarbons from tar sands with a mixture of light naphtha having from5 to 9 carbon atoms per molecule and methanol. The method disclosed inthe '668 patent is limited, in part, because it requires thesimultaneous use of two solvents, which increases processing costs andis less efficient in terms of bitumen recovery and solvent plus bitumencontent of the final tailings that are disposed.

U.S. Pat. No. 4,347,118 (the '118 patent) discloses a method in whichpentane is used to extract bitumen from tar sands. The method disclosedin the '118 patent requires the use of two fluidized bed drying zones.Operation of these fluidized bed drying zones requires a large amount ofenergy, limiting the efficiency of the overall method. Furthermore, thepentane solvent does not solubilize the asphaltene fraction of thebitumen that is not pentane soluble. Thus, this fraction of the bitumenis discharged with the tailings. For Athabasca type bitumen, this mayrange from 20 wt % to 40 wt % of the total initial hydrocarbon contentof the tar sands.

U.S. Pat. No. 5,143,598 (the '598 patent) discloses a method thatincludes adding heptane to tar sands to form a bitumen-rich heptanephase and then displacing the bitumen-rich heptane phase with water.This method utilizes steam vaporization and condensation, which arelow-efficiency processes. Also, the use of heptane, a non-aromaticsolvent, in this method can result in the precipitation of the heptaneinsoluble asphaltene fraction present in the bitumen phase. The heptaneinsoluble asphaltene fraction is discharged with the tailings. Inaddition, using water not only generates large amounts of aqueous wastebut also creates oil-water emulsions that are very difficult tobreakdown. The use of water can also introduce undesirable impuritiesinto bitumen, such as chlorine, and can result in undesirable swellingof clays in the tar sands. Furthermore, the bitumen recovered by thismethod typically has a low purity and requires additional processing,such as by centrifugation. This further increases the cost of theoverall recovery process.

The above issues may be mitigated or eliminated by separating bitumenfrom a material comprising bitumen by using a two step extractionprocess as disclosed in co-pending U.S. application Ser. Nos. 12/041,554and 11/249,234, both of which are incorporated herein by reference intheir entireties. The method generally comprises a first extraction stepwherein material comprising bitumen is mixed with a first solvent, andthe resulting mixture is separated into a bitumen-enriched solvent phaseand first solvent-wet tailings. The majority of the bitumen in thematerial comprising bitumen is contained in the bitumen-enriched solventphase. The first solvent may be, for example, a light aromatic solvent.The bitumen-enriched solvent phase may then undergo a further separationwherein the bitumen is separated from the first solvent. In a secondextraction step, the first solvent-wet tailings are mixed with a secondsolvent, and the resulting mixture is separated into a firstsolvent-enriched second solvent phase and second solvent-wet tailings.The majority of the first solvent in the first solvent-wet tailings arecontained in the first solvent-enriched second solvent phase. The secondsolvent may be a volatile hydrocarbon solvent. The second solvent-wettailings are then treated to remove any most, if not all, of the secondsolvent contained therein. The bitumen obtained from thebitumen-enriched solvent phase may then be subjected to furtherprocessing to upgrade the material into useful fuel products.

As can be seen from the above description, this two-step extractionprocess requires various supplies of solvents in order to carry out theseparation of bitumen from material comprising bitumen. Typically, thesolvents will need to be obtained from a third party, thus increasingthe overall cost of the process and making the manufacturing processdependent on an outside vendor. Factors such as these will tend toinflate the price of oil derived from material comprising bitumenaccording to the two step extraction process.

SUMMARY

Disclosed are embodiments of a method and system for obtaining lighthydrocarbon liquid distillate from material comprising bitumen. Thedisclosed method and system may include one or more solvent extractionsteps to separate bitumen from the material comprising bitumen, acracking step for cracking bitumen inside a nozzle reactor, and arecycling step to use the light hydrocarbon liquid distillate producedfrom cracking the bitumen in the nozzle reactor as the solvent in atleast one of the extraction steps. In some embodiments, such a methodand system may thereby become an essentially solvent free andself-sustaining method and system.

In some embodiments, a method includes forming a first mixture by mixinga first quantity of material comprising bitumen with a first solvent.The first mixture includes a bitumen-enriched solvent phase. The methodalso includes separating the bitumen-enriched solvent phase from thefirst mixture. Separation of the bitumen-enriched solvent phase resultsin the first mixture becoming first solvent-wet tailings. Thebitumen-enriched solvent phase includes bitumen component and the firstsolvent-wet tailings include a first solvent component. The method alsoincludes forming a light hydrocarbon liquid distillate and anon-participating hydrocarbon stream by cracking the bitumen componentof the bitumen-enriched solvent phase in a first nozzle reactor. Themethod can also include mixing the light hydrocarbon distillate with asecond quantity of material comprising bitumen.

In some embodiments, a method includes forming a first mixture by mixinga first quantity of material comprising bitumen with a first solvent.The first mixture includes a bitumen-enriched solvent phase. The methodalso includes separating the bitumen-enriched solvent phase from thefirst mixture. Separation of the bitumen-enriched solvent phase resultsin the first mixture becoming first solvent-wet tailings. Thebitumen-enriched solvent phase includes a bitumen component and aprimary first solvent component, and the first solvent-wet tailingsinclude a first solvent component. The method also includes separatingthe primary first solvent from the bitumen-enriched solvent phase.Separation of the primary solvent from the bitumen-enriched solventphase results in the isolation of the bitumen component of thebitumen-enriched solvent phase. The method can further include producingan asphaltene stream by deasphalting the bitumen component. The methodmay also include forming a light hydrocarbon liquid distillate and anon-participating hydrocarbon stream by cracking the asphaltene streamin a first nozzle reactor. Further, the method can also include mixingthe light hydrocarbon distillate with a second quantity of materialcomprising bitumen.

In some embodiments, a method includes solvent extracting a firstquantity of material comprising bitumen with at least one solvent toseparate bitumen from the first quantity of material comprising bitumen.The method also includes cracking the separated bitumen to form a lighthydrocarbon liquid distillate. The method can also include solventextracting a second quantity of material comprising bitumen with thelight hydrocarbon liquid distillate to separate bitumen from the secondquantity of material comprising bitumen.

In some embodiment, a method includes mixing a first quantity ofmaterial comprising bitumen with a first solvent. The method alsoincludes separating a bitumen-enriched solvent phase from a first resultof mixing the first solvent with the first quantity of materialcomprising bitumen. Additionally, the method includes separating a firstsolvent component from the bitumen-enriched solvent phase. The methodcan also include deasphalting a second result of separating the firstsolvent component from the bitumen-enriched solvent phase. Furthermore,the method includes feeding a third result of deasphalting the secondresult into a nozzle reactor. The method also includes mixing a portionof a fourth result of feeding the third result into a nozzle reactorwith a second quantity of material comprising bitumen.

In some embodiments, a method includes mixing a first quantity ofmaterial comprising bitumen with a first solvent. The method can alsoinclude separating a bitumen-enriched solvent phase from a first resultof mixing the first solvent with the first quantity of materialcomprising bitumen. The method can also include separating a firstsolvent component from the bitumen-enriched solvent phase. The methodfurther includes deasphalting a second result of separating the firstsolvent component from the bitumen-enriched solvent phase. Additionally,the method includes feeding a third result of deasphalting the secondresult into a nozzle reactor. Furthermore, the method includes mixing aportion of a fourth result of feeding the third result into a nozzlereactor with a second quantity of material comprising bitumen.

It is to be understood that the foregoing is a brief summary of variousaspects of some disclosed embodiments. The scope of the disclosure neednot therefore include all such aspects or address or solve all issuesnoted in the background above. In addition, there are other aspects ofthe disclosed embodiments that will become apparent as the specificationproceeds.

The foregoing and other features, utilities, and advantages of thesubject matter described herein will be apparent from the following moreparticular description of certain embodiments as illustrated in theaccompanying drawings. In this regard, it is to be understood that thescope of the invention is to be determined by the claims as issued andnot by whether given subject includes any or all features or aspectsnoted in this Summary or addresses any issues noted in the Background.

BRIEF DESCRIPTION OF THE DRAWINGS

The preferred and other embodiments are disclosed in association withthe accompanying drawings in which:

FIG. 1 is a flow chart depicting a method for obtaining bitumen;

FIG. 2 is a cross-section view of one embodiment of a nozzle reactor;

FIG. 3 is a flow chart depicting a method for obtaining bitumen;

FIG. 4 is a schematic diagram of a system and method for obtainingbitumen;

FIG. 5 is a schematic diagram of a system and method for obtainingbitumen;

FIG. 6 is a schematic diagram of a system and method for obtainingbitumen; and

FIG. 7 is a schematic diagram of a system and method for obtainingbitumen;

DETAILED DESCRIPTION

Before describing the details of the various embodiments herein, itshould be appreciated that the terms “solvent,” “a solvent” and “thesolvent” include one or more than one individual solvent compound unlessexpressly indicated otherwise. Mixing solvents that include more thanone individual solvent compounds with other materials can include mixingthe individual solvent compounds simultaneously or serially unlessindicated otherwise. It should also be appreciated that the term “tarsands” includes oil sands. The separations described herein can bepartial, substantial or complete separations unless indicated otherwise.All percentages recited herein are weight percentages unless indicatedotherwise.

Tar sands are used throughout this disclosure as a representativematerial comprising bitumen. However, the methods and system disclosedherein are not limited to processing of tar sands. Any materialcomprising bitumen may be processed by the methods and systems disclosedherein.

As shown in FIG. 1, a first embodiment of a method for obtaining bitumenfrom material comprising bitumen includes a first step 100 of mixing afirst quantity of material comprising bitumen with a first solvent toform a first mixture including a bitumen-enriched solvent phase, a step110 of separating the bitumen enriched solvent phase from the firstmixture and thereby producing first solvent-wet tailings, a step 120 ofcracking the bitumen component of the bitumen-enriched solvent phaseinside a first nozzle reactor to form a light hydrocarbon liquiddistillate and a non-participating hydrocarbon stream, and a step 130 ofmixing the light hydrocarbon liquid distillate with a second quantity ofmaterial comprising bitumen.

Step 100 of mixing a first quantity of material comprising bitumen witha first solvent to form a first mixture represents a solvent extractionstep (also sometimes referred to as dissolution, solvation, orleaching). Solvent extraction is a process of separating a substancefrom a material by dissolving the substance of the material in a liquid.In this situation, the material comprising bitumen is mixed with one ormore solvents to dissolve bitumen in the solvent and thereby separate itfrom the other components of the material comprising bitumen (e.g., themineral solids of tar sands).

The first solvent used in mixing step 100 may include a hydrocarbonsolvent. Any suitable hydrocarbon solvent or mixture of hydrocarbonsolvents that is capable of dissolving bitumen may be used. In certainembodiments, the hydrocarbon solvent is a hydrocarbon solvent that doesnot cause asphaltene precipitation. The hydrocarbon solvent or mixtureof hydrocarbon solvents can be economical and relatively easy to handleand store. The hydrocarbon solvent or mixture of hydrocarbon solventsmay also be generally compatible with refinery operations.

In some embodiments, the first solvent may be a light aromatic solvent.The light aromatic solvent may be an aromatic compound having a boilingpoint temperature less than about 400° C. at atmospheric pressure. Incertain embodiments, the light aromatic solvent used in the first mixingstep is an aromatic having a boiling point temperature in the range offrom about 75° C. to about 350° C. at atmospheric pressure, and morespecifically, in the range of from about 100° C. to about 250° C. atatmospheric pressure.

It should be appreciated that the light aromatic need not be 100%aromatic compounds. Instead, the light aromatic solvent may include amixture of aromatic and non-aromatic compounds. For example, the firstsolvent can include greater than zero to about 100 wt % aromaticcompounds, such as approximately 10 wt % to 100 wt % aromatic compounds,or approximately 20 wt % to 100 wt % aromatic compounds. In one example,the aromatic compounds include naphthalenes and/or cyclo-alkanes. Ageneral chemical formula for cyclo-alkanes is C_(n)H_(2(n+1−g)), where nis the number of C atoms and g is the number of rings in the molecule.

Any of a number of suitable aromatic compounds may be used as the firstsolvent. Examples of aromatic compounds that can be used as the firstsolvent include benzene, toluene, xylene, aromatic alcohols andcombinations and derivatives thereof. The first solvent can also includecompositions, such as kerosene, diesel (including biodiesel), gas oil(e.g., light gas oil (gas oil having boiling point temperature in therange of from 200° C. to 300° C.) or medium light gas oil (gas oilhaving boiling point temperature in the range of from 240° C. to 350°C.)), light distillate (distillate having boiling point temperature inthe range of from 140° C. to 260° C.), commercial aromatic solvents suchas Solvesso 100, Solvesso 150, and Solvesso 200 (also known in theU.S.A. as Aromatic 100, 150, and 200, including mainly C₁₀-C₁₁aromatics, and produced by ExxonMobil), and/or naphtha. Naphtha, forexample, is particularly effective at dissolving bitumen and isgenerally compatible with refinery operations. Some examples of keroseneinclude hydrocarbons having between 9 and 15 carbons per molecule. Someexamples of diesel include hydrocarbons having between 15 and 25 carbonsper molecule. Some examples of light or medium light gas oil includehydrocarbons having between 13 and 20 carbons per molecule. Someexamples of naphtha include hydrocarbons having between 4 and 12 carbonsper molecule. These examples are not intended to limit the generalmeanings of the respective terms.

The material comprising bitumen used in the mixing step may be anymaterial that includes bitumen. In certain embodiments, the materialcomprising bitumen includes any material including 3 wt % or more ofbitumen. Exemplary materials comprising bitumen include, but are notlimited to, tar sands, black shales, coal formations, and weatheredhydrocarbon sources contained in sandstones and carbonates. The materialcomprising bitumen may be obtained by any known means for obtainingmaterial comprising bitumen, such as by surface mining, undergroundmining, or any in situ extraction methods, such as vapor extraction(Vapex) and steam assisted gravity drainage (SAGD) extraction, and othersolvent and thermal extraction techniques.

The step 100 of mixing a first quantity of material comprising bitumenand a first solvent can be performed as a continuous, batch, orsemi-batch process. Continuous processing is typically used in largerscale implementations. However, batch processing may result in morecomplete separations than continuous processing.

The material comprising bitumen and the first solvent may be mixed byany suitable manner for mixing two materials for any suitable period oftime. The mixing 100 of the material comprising bitumen and the firstsolvent is preferably carried out to the point of dissolving most, ifnot all, of the bitumen contained in the material comprising bitumen. Incertain embodiments, the material comprising bitumen and the firstsolvent are mixed in a vessel to dissolve the bitumen and form the firstmixture. The vessel can be selectively opened or closed. The vessel usedfor mixing may also contain mechanisms for stirring and mixing solventand material comprising bitumen to further promote dissolution of thebitumen in the first solvent. For example, powered mixing devices suchas a rotating blade may be provided to mix the contents of the vessel.The vessel may also rotate about its axis to provide mixing, such as ina ball mill, or may be a grinding mill, such as described in U.S. Pat.No. 5,512,008.

The presence of water in the material comprising bitumen may impact theamount of power to be used when mixing the first solvent and materialcomprising bitumen to dissolve the bitumen in the first solvent.Material comprising bitumen may include from about 2 wt % to about 10 wt% water, and excessive mixing with the first solvent can result in theformation of certain water-solvent emulsions that can be quite stable.By controlling the amount of power used when mixing and the mixing time,the water content of the material comprising bitumen will stayassociated with the non-bitumen components of the material comprisingbitumen. Any mixing regime that produces a Reynolds number in excess of10,000 would likely result in the formation of certain water-solventemulsions. Additionally, it is expected that with tar sand clumps of 3inches or less, the mixing time should be limited to less than 30minutes to avoid emulsion formation.

In certain embodiments, material comprising bitumen and the firstsolvent are mixed by virtue of the manner in which the materialcomprising bitumen and the first solvent are introduced into the vessel.In this regard, the first solvent may be introduced into a vesselalready containing material comprising bitumen at a high velocity,thereby effectively agitating and mixing the contents of the vessel.Conversely, the material comprising bitumen may be introduced into avessel already containing first solvent. In some embodiments, the firstsolvent and material comprising bitumen are jointly introduced into arotating mill with a ball charge or a non-rotating vibratory mill withcharge of grinding or mixing media.

The amount of the first solvent added to the material comprising bitumenis a sufficient amount to effectively dissolve at least a portion, ordesirably all, of the bitumen in the material comprising bitumen. Insome embodiments, the amount of the first solvent mixed with thematerial comprising bitumen is approximately 0.5 to 3.0 times the amountof bitumen by volume contained in the material comprising bitumen,approximately 0.6 to 2.0 times the amount of the bitumen by volumecontained in the material comprising bitumen, or approximately 0.75 to1.5 times the amount of bitumen by volume contained in the materialcomprising bitumen.

It should be noted that the ratio of the first solvent to bitumen isaffected by the amount of bitumen in the material comprising bitumen.For example, when the material comprising bitumen is a high grade tarsands ore (e.g., greater than 12 wt % bitumen), the high grade tar sandsore can be processed with a solvent to bitumen weight ratio as low as2:1. However lower grade tar sands ore (e.g., 6 wt % bitumen) may beprocessed with a solvent to bitumen ratio greater than 3:1 to providesufficient liquid to fill up the open space between the particles.

The first mixture of the first solvent and the material comprisingbitumen generally results in the formation of a bitumen-enriched solventphase within the first mixture, with the majority of the bitumen fromthe material comprising bitumen dissolved in the bitumen-enrichedsolvent phase. In certain embodiments, 90%, preferably 95%, and mostpreferably 99% or more of the bitumen in the material comprising bitumenis dissolved in the first solvent and becomes part of thebitumen-enriched solvent phase.

Step 100 of mixing first solvent and material comprising bitumen may beperformed at any suitable temperature and pressure. In certainembodiments, it may be desirable to perform the mixing step at anincreased pressure to maintain the first solvent as a liquid during themixing. Additionally, performing the mixing step at higher temperaturesmay allow for the use of a wider range of suitable first solvents (e.g.,aromatic solvents having a boiling point temperature higher than 400°C.). Mixing at elevated temperatures may also enhance the kinetics ofthe dissolution process.

In step 110, the bitumen-enriched solvent phase is separated from thefirst mixture, Separation of the bitumen-enriched solvent phase from thefirst mixture results in the first mixture becoming first solvent-wettailings. Any suitable process for separating the bitumen-enrichedsolvent phase from the first mixture may be used, such as by filtering(including pressure and vacuum filtration), settling and decanting, orby gravity or gas overpressure drainage.

Separation of the bitumen-enriched solvent phase preferably does notinclude the separation of the water content of the first mixture.Because the water is heavier than the first solvent (specific gravity of1 for water versus specific gravity of ˜0.8 for first solvent), thewater will likely not be removed from the first mixture when thebitumen-enriched solvent phase is separated by the method disclosedabove.

In certain embodiments, the bitumen-enriched solvent phase removed fromthe first mixture includes from about 5 wt % to about 50 wt % of bitumenand from about 50 wt % to about 95 wt % of the first solvent. Thebitumen-enriched solvent phase includes little or no non-bitumencomponents of the material comprising bitumen (e.g., mineral solids).The first solvent-wet tailings created by removing the bitumen-enrichedsolvent phase from the first mixture may include from about 75 wt % toabout 95 wt % non-bitumen components of the material comprising bitumenand from about 5 wt % to about 25 wt % first solvent. The first solventcomponent of the first solvent-wet tailings represents first solventmixed with the material comprising bitumen but which is not removed fromthe first mixture during separation step 110. This first solventcomponent of the first solvent-wet tailings may have bitumen dissolvedtherein. Accordingly, in certain embodiments, the first solvent-wettailings may include from about 50 wt % to about 99 wt % of bitumen.

The vessel for mixing mentioned previously may function as both themixer and a separator for separating the bitumen-enriched solvent phasefrom the first mixture. Alternatively, separate vessels can be used formixing and separating, wherein the first mixture is transported from themixing vessel to a separation vessel. In certain embodiments, the vesselmay be divided into sections. One section may be used to mix thematerial comprising bitumen and the first solvent and another sectionmay be used to separate the bitumen-enriched solvent phase and the firstsolvent-wet tailings.

The separation of the bitumen-enriched solvent phase from the firstmixture can be performed as a continuous, batch, or semi-batch process.Continuous processing is typically used in larger scale implementations.However, batch processing may result in more complete separations thancontinuous processing.

Separation of the bitumen-enriched solvent phase from the first mixtureby any of the above-described methods may be preceded or followed byapplying pressurized gas over the first mixture. Applying a pressurizedgas over the first mixture facilitates the separation of thebitumen-enriched solvent phase from the non-bitumen components of thefirst solvent-wet tailings. Liberated bitumen-enriched solvent phase canthen be removed by applying additional first solvent to the firstsolvent-wet tailings as described in greater detail below. The additionof additional first solvent can, in some embodiments, displace theliberated bitumen-enriched solvent phase from the first solvent-wettailings. Applying a pressurized gas over the first mixture may alsoprovide a driving force for moving bitumen-enriched solvent phase out ofthe first mixture without the need for adding additional first solvent.Any suitable gas may be used. In certain embodiments, the gas isnitrogen, carbon dioxide or steam. The gas may also be added over thefirst mixture in any suitable amount. In certain embodiments, 62.5 ft³to 375 ft³ of gas per ton of material comprising bitumen is used. Thisis equivalent to a range of about 4.5 liters to 27 liters of gas perliter of material comprising bitumen. In some embodiments, 125 ft³ ofgas per ton of material comprising bitumen is used.

In certain embodiments, the bitumen-enriched solvent phase is separatedfrom the first mixture by filtering the first mixture with a plate andframe-type filter press. Any plate and frame-type filter press known tothose of ordinary skill in the art may be used. An exemplary plate andframe-type filter press suitable for use in this method is described inU.S. Pat. No. 4,222,873. Generally, the first mixture is pumped intoframe chamber located between two filter plates. The first mixture fillsthe frame chamber and the liquid component of the first mixture migratesout of the frame chamber through the filter cloths of each filter plate,thereby separating the liquid component of the first mixture from thesolid component of the first mixture. In this case, the liquid componentis the bitumen-enriched solvent phase (i.e., first solvent havingbitumen dissolved therein) and the solids component is the firstsolvent-wet tailings. The bitumen-enriched solvent phase that has passedout of the frame chamber is routed out of the plate and frame-typefilter press while the first solvent-wet tailings are left behind in theframe chamber.

When utilizing a plate and frame-type filter press to separate the firstmixture, pressurized gas may be injected into the frame chamber afterthe frame chamber has been filled with the first mixture to promote theseparation of the bitumen-enriched solvent phase from mineral solids inthe first mixture and the displacement of the bitumen-enriched solventphase from the first mixture. The introduction of pressurized gas intothe frame chamber may proceed according to the details provided abovefor applying pressurized gas over a first mixture.

In certain embodiments, step 110 includes a second separation stage inaddition to the separation described above. When the bitumen-enrichedsolvent phase is removed from the first mixture, a residual amount ofbitumen-enriched solvent phase may remain in the first mixture. Becausethe first mixture includes a residual amount of bitumen-enriched solventphase, the first mixture is now considered first solvent-wet tailings.Accordingly, the second separation stage is performed to remove theresidual bitumen-enriched solvent phase from the first solvent-wettailings.

The second separation stage may be performed by adding a second quantityof first solvent to the first solvent-wet tailings. The addition of asecond quantity of first solvent displaces the residual bitumen-enrichedsolvent phase and thereby forces the residual bitumen-enriched solventphase out of the first solvent-wet tailings. Some of the second quantityof the first solvent may remain in the first solvent-wet tailings, butlittle to no bitumen-enriched solvent phase remains. In this manner, thefirst solvent-wet tailings remain first solvent-wet tailings even afterthe second stage of separation, although the first solvent-wet tailingbecome essentially bitumen-free.

Any suitable amount of first solvent may be added to the firstsolvent-wet tailings in order to displace the bitumen-enriched solventphase. In certain embodiments, the second quantity of first solvent isadded to the first solvent-wet tailings in an amount of from about 10%to about 200% of the first quantity of first solvent mixed with thematerial comprising bitumen. The second quantity of first solvent mayalso be added to the first solvent-wet tailings in any suitable fashion.For example, where the first solvent-wet tailings remain loaded in theframe chamber of a plate and frame-type filter press as described above,the second quantity of first solvent may be added to the frame chamberto displace the residual bitumen-enriched solvent phase out of thefirst-solvent wet tailings and through the filter screens on either sideof the filter chamber.

The second quantity of first solvent may be the same first solvent asused in step 100 of mixing first solvent with the material comprisingbitumen. Alternatively, the second quantity of first solvent may be adifferent solvent from the first quantity of first solvent. However, thesecond quantity of first solvent is still of the type of first solventsdescribed in greater detail above (e.g., a light aromatic solvent).

The residual bitumen-enriched solvent phase displaced from the firstsolvent-wet tailings includes predominantly bitumen and first solvent.In certain embodiments, the residual bitumen-enriched solvent phaseincludes from about 5 wt % to about 50 wt % bitumen and from about 50 wt% to about 95 wt % first solvent. Little to no non-bitumen components ofthe material comprising bitumen is present in the residualbitumen-enriched solvent phase. After removal of the residualbitumen-enriched solvent phase, the first solvent-wet tailings includelittle or no bitumen. In certain embodiments, the first solvent-wettailings include from 0 wt % to about 2 wt % bitumen, from about 2 wt %to about 15 wt % first solvent, and from about 83 wt % to about 98 wt %non-bitumen components.

The residual bitumen-enriched solvent phase collected from the secondseparation stage may be combined with the bitumen-enriched solvent phasecollected from the first separation stage prior to any furtherprocessing conducted on the bitumen-enriched solvent phase.

In some embodiments, the second separation stage is carried out bywashing the first solvent-wet tailings with the second quantity of firstsolvent in a countercurrent process. The countercurrent processgenerally includes moving the first solvent-wet tailings in onedirection while passing the second quantity of first solvent through thefirst solvent-wet tailings in an opposite direction. For example, thefirst solvent-wet tailings may be loaded at the bottom of a screwclassifier conveyor positioned at an incline, while second quantity offirst solvent is introduced at the top of the screw classifier conveyor.An exemplary screw classifier conveyor suitable for use in this methodis described in U.S. Pat. No. 2,666,242. As the screw classifierconveyor moves the first solvent-wet tailings upwardly, the secondquantity of first solvent flows down the inclined screw classifierconveyor and passes through the first solvent-wet tailings. The secondquantity of first solvent displaces any residual bitumen-enrichedsolvent phase contained in the first solvent-wet tailings, thereby“washing” the bitumen from the first solvent-wet tailings.

Separation of the residual bitumen-enriched solvent phase and the firstsolvent-wet tailings naturally occurs based on the configuration of thescrew classifier conveyor, with the predominantly liquid residualbitumen-enriched solvent phase collecting at one end of the washing unitand the predominantly solid first solvent-wet tailings at the oppositeend of the washing unit. For example, when an inclined screw classifierconveyor is used, the residual bitumen-enriched solvent phase willcollect at the bottom of the screw classifier conveyor, while the firstsolvent-wet tailings will collect at the top of the screw classifierconveyor. The residual bitumen-enriched solvent phase includespredominantly bitumen and first solvent. In certain embodiments, theresidual bitumen-enriched solvent phase includes from about 5 wt % toabout 50 wt % bitumen and from about 50 wt % to about 95 wt % firstsolvent. The bitumen-enriched solvent phase may include relatively minoramounts of non-bitumen components of the material comprising bitumen.The first solvent-wet tailings include predominantly first solvent andnon-bitumen components of the material comprising bitumen. The firstsolvent component of the first solvent-wet tailings is first solventthat does not pass all the way through the first solvent-wet tailings inthe countercurrent washing process. In certain embodiments, the firstsolvent-wet tailings includes from about 5 wt % to about 20 wt % firstsolvent and from about 80 wt % to about 95 wt % non-bitumen components(e.g., mineral solids). The first solvent-wet tailings may include nobitumen, especially in the case where additional quantities of firstsolvent are added to the first solvent-wet tailings as described ingreater detail below.

The countercurrent process may include multiple stages. For example,after a first pass of first solvent through the first solvent-wettailings, the resulting residual bitumen-enriched solvent phase may bepassed through the first solvent-wet tailings several more times.Alternatively, additional quantities of fresh first solvent may bepassed through the first solvent-wet tailings one or more times. In thismanner, the residual bitumen-enriched solvent phase or fresh quantitiesof first solvent become progressively more enriched with bitumen aftereach stage and the first solvent-wet tailings lose progressively morebitumen after each stage.

Another suitable process for separating the bitumen-enriched solventphase from the first solvent includes loading the first mixture in avertical column and injecting a second quantity of first solvent intothe first mixture. More specifically, the second quantity of firstsolvent is injected into the first material at a top end of the verticalcolumn such that the second quantity of first solvent passes through thefirst material and displaces the bitumen-enriched solvent phase includedin the first material. The injection of the second quantity of firstsolvent results in the bitumen-enriched solvent phase exiting thevertical column at the bottom end of the vertical column where it may becollected.

Any method of loading the first mixture in the vertical column may beused. First mixture may be poured into the vertical column or, when anappropriate first mixture viscosity is obtained during the mixing of thefirst solvent and the material comprising bitumen, the first mixture maybe pumped into the vertical column. First mixture is generally loaded inthe vertical column by introducing the first mixture into the column atthe top end of the vertical column. The bottom end of the verticalcolumn is blocked, such as by a removable plug or by virtue of thebottom end of the vertical column resting against the floor. In certainembodiments, a metal filter screen at the bottom end of the verticalcolumn is used to maintain the first mixture in the vertical column. Assuch, introducing first mixture at the top end of the vertical columnfills the vertical column with first mixture. The amount of firstmixture loaded in the vertical column may be such that the first mixturesubstantially fills the vertical column with first mixture. In certainembodiments, first mixture is added to the vertical column to occupy 90%or more of the volume of the vertical column. In certain embodiments,the first mixture is not filled to the top of the vertical column sothat room is provided to inject first solvent, second solvent, etc.,into the vertical column.

The vertical orientation of the vertical column includes aligning thecolumn substantially perpendicular to the ground, but also includesorientations where the column forms angles less than 90° with theground. The column may generally be oriented at any angle that resultsin gravity aiding the flow of the first solvent, second solvent, etc.,from one end of the column to the other. In certain embodiments, thecolumn is oriented at an angle anywhere within the range of from about1° to 90° with the ground. In a preferred embodiment, the column isoriented at an angle anywhere within the range of from about 15° to 90°with the ground.

The material of the vertical column is also not limited. Any materialthat will hold the first mixture within the vertical column may be used.The material is also preferably a non-porous material such that variousliquids injected into the vertical column may only exit the column fromone of the ends of the vertical column. The material may be a corrosiveresistant material so as to withstand the potentially corrosivecomponents of the first mixture loaded in the column as well as anypotentially corrosive materials injected into the vertical column.

The shape of the vertical column is not limited to a specificconfiguration in all embodiments. Generally speaking, the verticalcolumn has two ends opposite one another, designated a top end and abottom end. The cross-section of the vertical column may be any shape,such as a circle, oval, square or the like. The cross-section of thevertical column may change along the height of the column, includingboth the shape and size of the vertical column cross-section. Thevertical column may be a straight line vertical column having no bendsor curves along the height of the vertical column. Alternatively, thevertical column may include one or more bends or curves.

Various dimensions may be used for the vertical column, including theheight, inner cross sectional diameter and outer cross sectionaldiameter of the vertical column. In certain embodiments, the ratio ofheight to inner cross sectional diameter may range from 0.5:1 to 15:1.

The second quantity of first solvent may be injected into the verticalcolumn by any suitable method. In certain embodiments, the secondquantity of first solvent is poured into the vertical column at the topend and allowed to flow down through the first mixture loaded thereinunder the influence of gravity.

The amount of first solvent added to the first mixture is not limited.The amount is preferably enough first solvent to displace most or all ofthe dissolved bitumen content of the first mixture. In certainembodiments, the second quantity of first solvent added to the firstmixture is from about 1.25 to about 2.25 times the amount of bitumen byvolume in the original material comprising bitumen.

Upon injection into the first mixture, the first solvent flowsdownwardly through the height of the column via small void spaces in thefirst mixture. The first solvent may flow downwardly through the forceof gravity or by an external force applied to the vertical column.Examples of external forces applied include the application of pressurefrom the top of the vertical column or the application of suction at thebottom of the vertical column.

In certain embodiments, the addition of first solvent is carried outunder flooded conditions. In other words, more first solvent is added tothe top of the vertical column than what flows down through the firstmixture, thereby creating a head of solvent at the top of the verticalcolumn.

In certain embodiments, the bitumen-enriched solvent exiting thevertical column includes from about 10 wt % to about 60 wt % bitumen andfrom about 40 wt % to about 90 wt % first solvent. Minor amounts ofnon-bitumen material may also be included in the bitumen-enrichedsolvent phase. In certain embodiments, 95% or more of the bitumen isremoved from the first mixture.

Various methods of collecting the bitumen-enriched solvent may be used,such as by providing a collection vessel at the bottom end of thevertical column. The bottom end of the vertical column may include ametal filter screen having a mesh size that does not permit firstmixture to pass through but which does allow for bitumen-enrichedsolvent to pass through and collect in a collection vessel located underthe screen. Collection of bitumen-enriched solvent may be carried outfor any suitable period of time. In certain embodiments, collection iscarried out for 2 to 30 minutes.

After injecting a second quantity of first solvent and collecting thebitumen-enriched solvent at the bottom of the vertical column,additional quantities of first solvent may be added to the verticalcolumn to extract additional bitumen from the first mixture. Repeatingthe addition of first solvent and collecting the resultantbitumen-enriched solvent phase may increase the overall extraction rateof bitumen from the first mixture. In certain embodiments, the use ofmultiple first solvent injection steps results in removing 99% or moreof the bitumen in the first mixture.

After separating the bitumen-enriched solvent phase from the firstmixture, a further step 120 may take place to crack at least a portionof the bitumen component of the bitumen-enriched solvent phase inside anozzle reactor. Cracking of the bitumen can produce a light hydrocarbonliquid distillate.

Nozzle reactors include any type of apparatus wherein differing types ofmaterials are injected into an interior reactor chamber of the nozzlereactor for the purpose of seeking to cause the materials to interactwithin the interior reactor chamber and achieve alteration of themechanical or chemical composition of one or more of the materials. Inthe instant embodiment, the bitumen-enriched solvent phase is injectedinto the interior reactor chamber of the nozzle reactor along with acracking material, wherein the two materials interact to crack thebitumen component of the bitumen-enriched solvent phase and producelighter hydrocarbon material.

Various types of nozzle reactor suitable for cracking hydrocarbons suchas bitumen may be used. In certain embodiments, the nozzle reactor is anozzle reactor as disclosed in co-pending U.S. application Ser. No.11/233,385, hereby incorporated by reference in its entirety. The nozzlereactor of U.S. application Ser. No. 11/233,385 may generally include aninterior reactor chamber, an injection passage, and a material feedpassage. The interior reactor chamber includes an injection end and anejection end. The injection passage is mounted in the nozzle reactor inmaterial injecting communication with the injection end of the interiorreactor chamber. The injection passage has an enlarged volume injectionsection, an enlarged volume ejection section, and a reduced volumemid-section intermediate the enlarged volume injection section andenlarged volume ejection section. The injection passage also has amaterial injection end and a material ejection end, with the materialejection end being in injecting communication with the interior reactorchamber. The material feed passage penetrates the interior reactorchamber and is generally located adjacent to the material ejection endof the injection passage. Additionally, the material feed passage isaligned so as to be transverse to the axis of the injection passage axisextending from the material injection end to the material ejection endin the injection passage.

FIG. 2 illustrates a nozzle reactor disclosed in U.S. application Ser.No. 11/233,385 that is suitable for use in this embodiment. The nozzlereactor, indicated generally at 10, has a reactor body injection end 12,a reactor body 14 extending from the reactor body injection end 12, andan ejection port 13 in the reactor body 14 opposite its injection end12. The reactor body injection end 12 includes an injection passage 15extending into the interior reactor chamber 16 of the reactor body 14.The central axis A of the injection passage 15 is coaxial with thecentral axis B of the interior reactor chamber 16.

The injection passage 15 has a circular diametric cross-section and, asshown in the axially-extending cross-sectional view of FIG. 2, opposinginwardly curved side wall portions 17, 19 (i.e., curved inwardly towardthe central axis A of the injection passage 15) extending along theaxial length of the injection passage 15. In certain embodiments, theaxially inwardly curved side wall portions 17, 19 of the injectionpassage 15 allow for a higher speed of injection gas when passingthrough the injection passage 15 into the interior reactor chamber 16.

The side wall of the injection passage 15 can provide one or more among:(i) uniform axial acceleration of cracking material passing through theinjection passage; (ii) minimal radial acceleration of such material;(iii) a smooth finish; (iv) absence of sharp edges; and (v) absence ofsudden or sharp changes in direction. The side wall configuration canrender the injection passage 15 substantially isentropic.

A material feed passage 18 extends from the exterior of the reactor body14 toward the interior reaction chamber 16 transversely to the axis B ofthe interior reactor chamber 16. The material feed passage 18 penetratesan annular material feed port 20 adjacent the interior reactor chamberwall 22 at the interior reactor chamber injection end 24 abutting thereactor body injection end 12. The material feed port 20 includes anannular, radially extending reactor chamber feed slot 26 inmaterial-injecting communication with the interior reactor chamber 16.The material feed port 20 is thus configured to inject feed material:(i) at about a 90° angle to the axis of travel of cracking materialinjected from the injection passage 15; (ii) around the entirecircumference of a cracking material injected through the injectionpassage 15; and (iii) to impact the entire circumference of the freecracking material stream virtually immediately upon its emission fromthe injection passage 15 into the interior reactor chamber 16.

The annular material feed port 20 may have a U-shaped or C-shapedcross-section among others. In certain embodiments, the annular materialfeed port 20 may be open to the interior reactor chamber 16, with noarms or barrier in the path of fluid flow from the material feed passage18 toward the interior reactor chamber 16. The junction of the annularmaterial feed port 20 and material feed passage 18 can have a radiusedcross-section.

The interior reactor chamber 16 can be bounded by stepped, telescopingside walls 28, 30, 32 extending along the axial length of the reactorbody 14. In certain embodiments, the stepped side walls 28, 30, 32 areconfigured to: (i) allow a free jet of injected cracking material, suchas superheated steam, natural gas, carbon dioxide, or other gas, totravel generally along and within the conical jet path C generated bythe injection passage 15 along the axis B of the interior reactorchamber 16, while (ii) reducing the size or involvement of back flowareas, e.g., 34, 36, outside the conical or expanding jet path C,thereby forcing increased contact between the high speed crackingmaterial jet stream within the conical jet path C and feed material,such as heavy hydrocarbons, injected through the annular material feedport 20.

As indicated by the drawing gaps 38, 40 in the embodiment of FIG. 2, thereactor body 14 has an axial length (along axis B) that is much greaterthan its width. In the FIG. 2 embodiment, exemplary length-to-widthratios are typically in the range of 2 to 7 or more.

The dimensions of the various components of the nozzle reactor shown inFIG. 2 are not limited, and may generally be adjusted based on theamount of material feed to be cracked inside the nozzle reactor. Table 1provides exemplary dimensions for the various components of the nozzlereactor based on the hydrocarbon input in barrels per day (BPD).

TABLE 1 Material Feed Input (BPD) Nozzle Reactor Component (mm) 5,00010,000 20,000 Injection Passage, Enlarged Volume 148 207 295 InjectionSection Diameter Injection Passage, Reduced Volume 50 70 101 Mid-SectionDiameter Injection Passage, Enlarged Volume 105 147 210 Ejection SectionDiameter Injection Passage Length 600 840 1,200 Interior Reactor ChamberInjection 187 262 375 End Diameter Interior Reactor Chamber Ejection1,231 1,435 1,821 End Diameter Interior Reactor Chamber Length 6,4007,160 8,800 Overall Nozzle Reactor Length 7,000 8,000 10,000 OverallNozzle Reactor Outside 1,300 1,600 2,000 Diameter Overall Nozzle ReactorLength to 5.4 5.0 5.0 Outside Diameter Ratio

As used in the method of this embodiment, the nozzle reactor isgenerally operated by injecting bitumen-enriched solvent phase into theinterior reactor chamber 16 via the material feed passage 18. At least aportion of the bitumen-enriched solvent phase, including at least aportion of the bitumen component, is injected into the reactor bodypassage 16 is in a liquid phase. The bitumen-enriched solvent phase maybe pretreated prior to injection into the interior reactor chamber 16 inorder to alter the amount or fraction of bitumen-enriched solvent phasethat is in a liquid phase. In certain embodiments, the temperatureand/or pressure of the bitumen-enriched solvent phase is adjusted toalter the amount of bitumen-enriched solvent phase in the liquid phaseprior to injection. The non-liquid portion of the bitumen-enrichedsolvent phase is typically injected into the interior reactor chamber 16in a gaseous phase.

As the bitumen-enriched solvent phase is injected into the interiorreactor chamber 16, a cracking material is injected into the interiorreactor chamber 16 by way of the injection passage 15. The configurationof the injection passage 15 is such that the cracking material isaccelerated to a supersonic speed and enters the interior reactorchamber 16 at supersonic speed. Shock waves are produced by the crackingmaterial traveling at supersonic speeds, and the shock waves crack thelargest hydrocarbon molecules present in the bitumen component of thebitumen-enriched solvent phase entering the interior reactor chamber 16via the material feed passage 18. In this manner, bitumen may be brokendown into lighter hydrocarbon molecules.

In certain embodiments, about 10% to about 95% of the bitumen injectedinto the interior reactor chamber 16 is cracked and broken down intolighter hydrocarbon products. The cracking of bitumen produceshydrocarbons having lower molecular weight than the bitumen. In certainembodiments, the bitumen is broken down into light hydrocarbon liquiddistillate. The light hydrocarbon liquid distillate includeshydrocarbons having a molecular weight less than about 300 Daltons. Incertain embodiments, about 30% to about 60% of the bitumen crackedinside the interior reactor chamber 16 is cracked into light hydrocarbonliquid distillate.

Other portions of the bitumen-enriched solvent phase (e.g., lowermolecular weight molecules) injected into the interior reactor chamber16 may pass through the nozzle reactor without being cracked. Often,some fraction of the bitumen-enriched solvent phase that is injectedinto the interior reactor chamber 16 may pass through the nozzle reactoruncracked because of kinetic limitations. These portions of thebitumen-enriched solvent phase may be referred to as non-participatinghydrocarbon, since the shock waves produced by the injection of thecracking material through the injection passage 15 do not act on thismaterial to crack it into lighter hydrocarbon material. Bitumen that iscracked but not cracked into light hydrocarbon distillate may also bereferred to as non-participating hydrocarbon. In certain embodiments,about 40% to about 70% of the bitumen injected into the interior reactorchamber 16 is not cracked and exits the nozzle reactor asnon-participating hydrocarbon.

In certain embodiments, the light hydrocarbon distillate and thenon-participating hydrocarbon exiting the nozzle reactor may betransported to a separation unit that separates the hydrocarbondistillate from the non-participating hydrocarbon. The separation unitmay be any suitable separator capable of separating the two streams.Examples of suitable separation units include, but are not limited to,distillation units, vacuum towers, gravity separation units, filtrationunits, and cyclonic separation units.

In certain embodiments, the non-participating hydrocarbon stream thatexits the nozzle reactor and is separated from the light hydrocarbondistillate may be subjected to further processing to upgrade thenon-participating hydrocarbon into useful material. Various types ofprocessing may be performed on the non-participating hydrocarbon forupgrading the non-participating hydrocarbon. In one example, thenon-participating hydrocarbon is injected into a second nozzle reactoror recycled back into the first nozzle reactor. Where thenon-participating hydrocarbon is injected into a second nozzle reactor,the structure of the second nozzle reactor may be similar or identicalto the first nozzle reactor described in greater detail above. Thedimensions of the second nozzle reactor may be identical to thedimensions of the first nozzle reactor, or the dimensions of the secondnozzle reactor may be scaled up or down from the dimensions of the firstnozzle reactor. The non-participating hydrocarbon stream may also bepretreated prior to injecting the hydrocarbon stream into the secondnozzle reactor in order to alter the amount of non-participatinghydrocarbon entering the second nozzle reactor in the liquid phase. Suchfurther treatment of non-participating hydrocarbon is discussed ingreater detail in co-pending U.S. application Ser. No. 12/466,923.

Not all of the bitumen component of the bitumen-enriched solvent phaseneed be cracked in a nozzle reactor to produce light hydrocarbondistillate. A portion of the bitumen may be upgraded. Upgrading of thebitumen may comprise any processing that generally produces a stableliquid (i.e., synthetic crude oil) and any subsequent refinement ofsynthetic crude oil into petroleum products. The process of upgradingbitumen to synthetic crude oil may include any processes known to thoseof ordinary skill in the art, such as heating or cracking the bitumen toproduce synthetic crude. The process of refining synthetic crude mayalso include any processes known to those of ordinary skill in the art,such as distillation, hydrocracking, hydrotreating and coking. Theypetroleum products produced by the upgrading process are not limited,any may include petroleum, diesel fuel, asphalt base, heating oil,kerosene, and liquefied petroleum gas.

Referring back to FIG. 1, step 130 includes mixing the light hydrocarbondistillate produced in the first nozzle reactor with a further quantityof material comprising bitumen. The light hydrocarbon distillate may actas a solvent capable of dissolving bitumen, and therefore can be used inthe first mixing step 100 described above. In certain embodiments, thelight hydrocarbon distillate can supplement or eliminate the firstsolvent used to dissolve bitumen in the first step of the method of thisembodiment to thereby reduce or eliminate the need for obtaining firstsolvent from a third party when carrying out a solvent extraction stepon the material comprising bitumen.

The manner in which the light hydrocarbon is mixed with a furtherquantity of material comprising bitumen may be similar or identical toany of the manners of mixing described above with respect to step 100and the mixing of the first solvent with the first quantity of materialcomprising bitumen.

Although not depicted in FIG. 1, the method of this embodiment mayinclude further steps for processing the first solvent-wet tailings toremove the first solvent from the tailings. As noted above, the firstsolvent-wet tailings may include from about 5 wt % to about 25 wt % ofthe first solvent Removing the first solvent from the tailings mayproduce a more environmentally friendly tailings product.

Accordingly, the method may further include a step of separating thefirst solvent component of the first solvent-wet tailings from the firstsolvent-wet tailings by adding a second solvent to the first solvent-wettailings. Removal of the first solvent with a second solvent displacesthe first solvent from the first solvent-wet tailings. Some secondsolvent added to the first solvent-wet tailings may remain therein,which results in the first solvent-wet tailings becoming secondsolvent-wet tailings. The second solvent component of the secondsolvent-wet tailings may be also be removed to thereby producesolvent-free tailings.

The second solvent can be any suitable solvent that is useful fordisplacing the first solvent. In certain embodiments the second solventhas a lower vapor pressure than the first solvent to enhance removal ofthe second solvent in subsequent processing steps. In certainembodiments, the second solvent may be a hydrocarbon solvent. Anysuitable hydrocarbon solvent or mixture of hydrocarbon solvents that iscapable of displacing the first solvent may be used. The hydrocarbonsolvent or mixture of hydrocarbon solvents can be economical andrelatively easy to handle and store. The hydrocarbon solvent or mixtureof hydrocarbon solvents may also be generally compatible with refineryoperations.

In certain embodiments, the second hydrocarbon solvent can include oneor more volatile hydrocarbon solvents. Volatile hydrocarbon solventsgenerally include hydrocarbons having a boiling point temperaturebetween about −20° C. and 150° C. Volatile hydrocarbon solvents may alsoinclude aliphatic compounds that are capable of solvating bitumen and/orthe first solvent. These aliphatic compounds can include compounds suchas branched or unbranched alkanes or alkenes. Any of these aliphaticcompounds can be functionalized or non-functionalized. In certainembodiments, the second solvent includes one or more aliphatichydrocarbons having 3 to 9 carbon atoms. In some embodiments, the secondsolvent includes aliphatic hydrocarbons having no more than 9 carbonatoms. The second solvent may also include lower carbon paraffins, suchas cyclo- and iso-paraffins having 3 to 9 carbon atoms. The secondsolvent may include one or more of any of the following compounds:methane, ethane, propane, butane, and/or pentane, alkene equivalents ofthese compounds and/or combinations and derivatives thereof.

In certain embodiments, the second solvent includes liquefied petroleumgas (LPG). The term “liquefied petroleum gas” is used broadly herein torefer to any hydrocarbon gas (hydrocarbons that are gases at ambienttemperature (25° C.) and pressure (1 atm) and has been compressed toform a liquid. Preferably, the LPG is primarily or even entirely propaneor predominantly or entirely butane. However, other LPG formulations arecontemplated including commercially available formulations. Thecomposition of common commercial LPG can vary depending on the time ofthe year, geographical location, etc. Commercial LPG is a naturalderivative of both natural gas and crude oil. Often, LPG is a mixture ofpropane and butane (n-butane and/or i-butane) with small amounts ofpropylene and butylene (any one or combination of the four isomers). Apowerful odorant such as ethanethiol is typically added to make it easyto detect leaks. Commercial LPG also often contains very small amountsof lighter hydrocarbons, such as ethane and ethylene, and heavierhydrocarbons such as pentane.

Three examples of commercial LPG are shown below in Table 2.

TABLE 2 Examples of Commercially Available LPG Commercial CommercialButane/ Component HD-5 Propane Propane Propane Mixture Lighter Min 90v-% propane Mixture of propane Mixture of butane Hydrocarbons Max v-5%propylene and/or propylene and/or butylenes and propane and/orpropylenes Butane and 2.5 v-% 2.5 v-% — heavier hydrocarbons Pentane and— — Max v-2% heavier hydrocarbons Residual matter 0.05 ml 0.05 ml —Total Sulfur 123 w-PPM 185 w-PPM 140 w-PPM

LPG is stored and transported under pressure to maintain thehydrocarbons as liquids. In certain embodiments, LPG has a boiling pointat atmospheric pressure of approximately −80° C. to 10° C., desirably,approximately −55° C. to 5° C., or, suitably, approximately −35° C. to−5° C.

Adding second solvent to the first solvent-wet tailings may be carriedout in any suitable manner that results in first solvent displacementfrom the first solvent-wet tailings. In certain embodiments, secondsolvent may be added to the first solvent-wet tailings in a similar oridentical manner to the addition of first solvent to the firstsolvent-wet tailings described in greater detail above. In certainembodiments, the second solvent is added to the first solvent-wettailings without overly agitating the first solvent-wet tailings inorder to avoid the formation of water-solvent emulsions as discussed ingreater detail above.

The amount of the second solvent added to the first solvent-wet tailingsis sufficient to effectively displace at least a portion, or desirablyall, of the first solvent in the first solvent-wet tailings. The amountof second solvent added to the first solvent-wet tailings isapproximately 0.5 to 1 times the amount of bitumen by volume originallycontained in the material comprising bitumen.

In certain embodiments, the addition of second solvent to the firstsolvent-wet tailings results in the removal of 95% or more of the firstsolvent in the first solvent-wet tailings. The first solvent may leavethe first solvent-wet tailings as a first solvent-second solventmixture. The first solvent-second solvent mixture may include from about5 wt % to about 50 wt % first solvent and from about 50 wt % to about 95wt % second solvent. The removal of the first solvent from the firstsolvent-wet tailings through the addition of second solvent may resultin a quantity of second solvent not passing all the way through thefirst solvent-wet tailings. Consequently, the first solvent-wet tailingsbecome a second solvent-wet tailings upon separation of the firstsolvent. In certain embodiments, the second solvent-wet tailings includefrom about 70 wt % to about 95 wt % non-bitumen components and fromabout 5 wt % to about 30 wt % second solvent.

As with previously described separation steps, separation of the firstsolvent from the first solvent-wet tailings by adding second solvent maybe preceded or followed by applying pressurized gas over the firstsolvent-wet tailings. Applying a pressurized gas over the firstsolvent-wet tailings facilitates the separation of the first solventcomponent of the first solvent-wet tailings from the non-bitumencomponents of the first solvent-wet tailings. The liberated firstsolvent can then be displaced from the first solvent-wet tailings byapplying additional second solvent to the first solvent-wet tailings.Applying a pressurized gas over the first mixture may also provide adriving force for moving bitumen-enriched solvent phase out of the firstmixture without the need for adding additional first solvent. Anysuitable gas may be used. In certain embodiments, the gas is nitrogen,carbon dioxide or steam. The gas may also be added over the secondmixture in any suitable amount. In certain embodiments, 62.5 ft³ to 375ft³ of gas per ton of material comprising bitumen is used. This isequivalent to a range of about 4.5 liters to 27 liters of gas per literof material comprising bitumen. In some embodiments, 125 ft³ of gas perton of material comprising bitumen is used.

In certain embodiments, separation of the first solvent from the firstsolvent-wet tailings utilizes a plate and frame-type filter press. Theplate and frame-type filter press may be a separate plate and frame-typefilter press from the plate and frame-type filter press used to separatethe bitumen-enriched solvent phase from the first mixture and/or thefirst solvent-wet tailings, or the same plate and frame-type filterpress may be used to separate the bitumen-enriched solvent phase fromthe first mixture (or first solvent-wet tailings) and to separate thefirst solvent from the first solvent-wet tailings. When the same plateand frame-type filter press is used, the method may include addingsecond solvent to the first solvent-wet tailings still contained in theframe chamber. In other words, the method need not necessarily alwaysinclude a step of removing the first solvent-wet tailings from the plateand frame-type filter press before mixing with second solvent. Thesecond solvent may be pumped into the plate and frame-type filter presswhere it displaces the first solvent component of the first solvent-wettailings located in the frame chambers.

When utilizing a plate and frame-type filter press to separate the firstsolvent from the first solvent-wet tailings, pressurized gas may beinjected into the frame chamber after the frame chamber has been filledwith the first solvent-wet tailings. In certain embodiments, injectingpressurized gas into the first solvent-wet tailings can promote theseparation of the first solvent from mineral solids in the firstsolvent-wet tailings. The process for adding gas can be similar oridentical to the method described above with respect to separation ofthe bitumen-enriched solvent phase from the first mixture (or firstsolvent-wet tailings) in a plate and frame-type filter press.

The second solvent passes through the first solvent-wet tailings loadedin the frame chamber and displaces the first solvent. In certainembodiments, 95% or more of the first solvent in the first solvent-wettailings is displaced by the second solvent. This first solvent passesthrough the filter clothes and out of the frame chamber. Some of thesecond solvent can also pass through the filter clothes, while somesecond solvent can remain in the frame chamber. Consequently, the firstsolvent-wet tailings become second solvent-wet tailings.

The separation of first solvent from the first solvent-wet tailingsthrough the addition of second solvent may also be carried out as acountercurrent washing process. The countercurrent process generallyincludes moving the first solvent-wet tailings in one direction whilepassing the second solvent through the first solvent-wet tailings in anopposite direction. For example, the first solvent-wet tailings may beloaded at the bottom of a screw classifier conveyor positioned at anincline, while second solvent is introduced at the top of the inclinedscrew classifier conveyor. As the screw classifier conveyor moves thefirst solvent-wet tailings upwardly, the second solvent flows down theinclined screw classifier conveyor and passes through the firstsolvent-wet tailings. The two materials mix and first solvent isdisplaced by the second solvent, thereby “washing” the first solventfrom the first solvent-wet tailings. In certain embodiments, 85% or moreof the first solvent in the first solvent-wet tailings is displaced bythe second solvent. The first solvent-second solvent mixture thatcollects at one end of the screw classifier conveyor may include fromabout 5 wt % to about 50 wt % first solvent and from about 50 wt % toabout 95 wt % second solvent. Some of the second solvent may remain withthe tailings, thereby forming the second solvent-wet tailings thatcollect at the opposite end of the screw classifier conveyor. In certainembodiments, the second solvent-wet tailings includes from about 10 wt %to about 30 wt % second solvent and from about 70 wt % to about 90 wt %non-bitumen components.

The countercurrent process may include multiple stages as described ingreater detail above with respect to washing the first mixture or firstsolvent-wet tailings. In a multiple stage countercurrent process, thesecond solvent can displace progressively more first solvent after eachstage and the first solvent-wet tailings lose progressively more firstsolvent after each stage.

When separation of the bitumen-enriched solvent phase from the firstmixture is carried out using a vertical column as described in greaterdetail above, the first solvent component included in the firstsolvent-wet tailings loaded in the vertical column may be separated, atleast to some degree, from the first solvent-wet tailings by injectingthe second solvent at the top end of the vertical column. In thismanner, second solvent may flow down through the vertical column anddisplace the first solvent contained in the first solvent-wet tailingsloaded in the vertical column. A mixture of first solvent and secondsolvent may be collected at the bottom end of the vertical column, whilesome second solvent may remain in the vertical column, leading the firstsolvent-wet tailings to become second solvent-wet tailings.

The second solvent may be injected into the vertical column by anysuitable method. In certain embodiments, the first quantity of secondsolvent is poured into the vertical column at the top end and allowed toflow down through the first mixture loaded therein. The downward flow ofthe second solvent can be allowed to progress under the force of gravityor external forces may be applied, such as pressure at the top of thevertical column or suction at the bottom of the vertical column.

The amount of second solvent added can vary. In some embodiments, theamount is preferably enough second solvent to displace most or all ofthe first solvent contained in the first solvent-wet tailings loaded inthe vertical column. In certain embodiments, the first quantity ofsecond solvent added to the first mixture is from about 0.5 to about2.0, and preferably about 1 times the amount of bitumen by volumecontained in the original material comprising bitumen. If multiplesecond solvent addition steps are performed, then the total amount ofsecond solvent added is about 1.0 times the amount of bitumen by volumecontained in the original material comprising bitumen.

The mixture of first solvent and second solvent that flows downwardlythrough the height of the column may exit the bottom end of the verticalcolumn where it may be collected for further use and processing. Incertain embodiments, the mixture of first solvent and second solventincludes from about 50 wt % to about 90 wt % second solvent and fromabout 10 wt % to about 50 wt % first solvent. Minor amounts of bitumenand non-bitumen material may also be included in the mixture of firstsolvent and second solvent.

In certain embodiments, the addition of second solvent is carried outunder flooded conditions. In other words, more second solvent is addedto the top of the vertical column than what flows down through the firstmixture, thereby creating a head of solvent at the top of the verticalcolumn.

Various methods of collecting the mixture of first solvent and secondsolvent may be used, such as by providing a collection vessel at thebottom end of the vertical column. The bottom end of the vertical columnmay include a metal filter screen having a mesh size that does notpermit the tailings to pass through but which does allow for the mixtureof first solvent and second solvent to pass through and collect in acollection vessel located under the screen. Collection of the mixture offirst solvent and second solvent may be carried out for any suitableperiod of time. In certain embodiments, collection is carried out for 2to 30 minutes.

Additional quantities of second solvent can be added to the verticalcolumn to increase the removal of first solvent. In other words, afterinjecting a first quantity of second solvent and collecting the mixtureof first solvent and second solvent at the bottom of the verticalcolumn, additional quantities of second solvent may be added to thevertical column to displace additional first solvent from the tailingsloaded in the vertical column. In certain embodiments, the use ofmultiple second solvent injection steps may result in removing 99% ormore of the first solvent in the first solvent-wet tailings.

Once the second solvent-wet tailings are obtained, the second solventcomponent of the second solvent-wet tailings may be removed from thesecond solvent-wet tailings to thereby produce a more environmentallyfriendly tailings product. Various manners of removing second solventfrom the second solvent-wet tailings may be used. In certainembodiments, the second solvent can be removed from the secondsolvent-wet tailings by flashing or heating the second solvent-wettailings. In this manner, second solvent evaporates from the secondsolvent-wet tailings and leaves behind solvent-dry, stackable tailings.In some embodiments, pre-heated gas, such as nitrogen, may be injectedinto the second solvent-wet tailings to remove the second solvent. Thepre-heated gas may be at a temperature above the boiling pointtemperature of the second solvent. Separation of the second solvent fromthe second solvent-wet tailings may result in 95% or more of the secondsolvent in the second solvent-wet tailings being removed.

When the second solvent is a volatile hydrocarbon, the energy requiredto remove the second solvent may be minimal. In certain embodiments, thesecond solvent may be removed from the second solvent-wet tailings atroom temperature. Separation of the second solvent at room temperatureor any temperature under the boiling point temperature of water is alsouseful for avoiding the removal of water from the tailings.

Separating second solvent from the second solvent-wet tailings may alsoinclude separation of any first solvent included in the secondsolvent-wet tailings. Separation of the first solvent may occur togetherwith the separation of the second solvent, such as by heating orflashing the second-solvent wet tailings in a manner causing bothsolvents to evaporate from the second-solvent wet tailings.Alternatively, the separation may be incremental, wherein the flashingor heating is carried out to start with at conditions that will causeonly the second solvent to evaporate, followed by adjusting theconditions to cause the evaporation of the first solvents. The first andsecond solvents separated from the second solvent-wet tailings may berecovered and recycled within the method.

The solvent-dry, stackable tailings resulting from removal of the secondsolvent from the second solvent-wet tailings may generally includeinorganic solids, such as sand and clay, water, and little to no firstand second solvent. As used herein, the term “solvent-dry” meanscontaining less than 0.1 wt % total solvent. As used herein, the term“stackable” means having a water content of from about 2 wt % to about15 wt %. This range of water content creates a damp tailings that willnot produce significant amounts of dust when transporting or depositingthe tailings. This range of water content may also provide stackabletailings that will not flow like dry sand, and therefore have theability to be retained within an area without the need for retainingstructures (e.g., a tailings pond). This range of water content alsoprovides tailings that are not so wet as to be sludge-like orliquid-like. The solvent-dry, stackable tailings produced by the abovedescribed method may also include less than 2 wt % bitumen andasphaltene.

In another variation of the above described method, the bitumen-enrichedsolvent phase may be separated into a bitumen component and a firstsolvent phase prior to cracking the bitumen component inside the firstnozzle reactor to produce light hydrocarbon distillate. In certainembodiments, 90% or more of the first solvent in the bitumen-enrichedfirst solvent phase may be separated from the bitumen-enriched solventphase to produce a bitumen component.

Separation of the bitumen and the first solvent may be by any suitableseparation method that is capable of separating the first solvent fromthe bitumen component. In certain embodiments, separation may beachieved by heating the bitumen-enriched solvent phase and separatingfirst solvent from bitumen based on the boiling point temperature of thefirst solvent. The heat can be provided by any suitable heating source,such as by a heat exchanger. Heating can be done substantially atambient pressure, at a pressure less than ambient, or at a pressuregreater than ambient. In certain embodiments, the separation of thefirst solvent and the bitumen is accomplished by a distillation tower.

Table 3 shows the boiling points of some of the components that may beused as or included in the first solvent. In certain embodiments, thebitumen-enriched solvent phase may be heated to a temperature ofapproximately 70° C. to 350° C., such as approximately 100° C. to 350°C., approximately 125° C. to 250° C., or, desirably, approximately 140°C. to 220° C.

TABLE 3 Solvent Boiling Points Boiling Compound Point ° C. Fatty AcidMethyl Esters C8 187 C10 224 C12 262 C14 295 C16 338 C18 352 AromaticHydrocarbons Toluene 111 Xylene 140 Coal Tar Naphtha 150-220 PetroleumNaphtha 172-215 Light distillate 140-260 Middle distillate 200-400Aromatic/Solvesso 100 160-170 Aromatic/Solvesso 150 185-205Aromatic/Solvesso 200 240-275

In some embodiments, separation may be accomplished by utilizing amulti-hearth solvent recovery furnace. Multi-hearth solvent recoveryfurnaces typically include alternating arrangements of centrally locatedhearths and peripherally located hearths. The hearths can be heated, forexample, with oil fired muffles and/or high pressure steam coils. Insome embodiments, hearths near the top of the furnace may be heated tohigher temperatures than hearths closer to the bottom of the furnace.

In certain embodiments, the bitumen-enriched solvent phase may be routedto a separator to recover the first solvent. The separator may separatethe first solvent from bitumen product. The separator may also beconfigured to separate any water and mineral solids that might bepresent in bitumen-enriched solvent phase. Separation of thebitumen-enriched solvent phase may also be configured to functiondespite the presence of fine solid material. For example, a separatorused to separate the first solvent from the bitumen can include asuitable packing material, such as vertical slats, to provide increasedsurface area for condensation and evaporation. This packing material canbe resistant to clogging by the fine solid material. In thoseembodiments where the separation is accomplished by utilizing adistillation tower, the fine solid materials may fall to the bottom andbe cleaned out periodically.

Just as with previous separation and mixing steps, separation of firstsolvent from bitumen can be performed as a continuous, batch, orsemi-batch process. Continuous processing is typically used in largerscale implementations. However, batch processing may result in morecomplete separations than continuous processing.

Once the first solvent is separated from the bitumen, the first solventmay be recycled for further use in the same process or collected for usein other processes. When recycled for use in the same process, the firstsolvent may be transported back to, for example, a first vessel used tomix the material comprising bitumen and the first solvent. The recycledfirst solvent may be used to supplement or replace a fresh source offirst solvent used in the first mixing step. The recycled first solventmay also be used with the light hydrocarbon liquid distillate toeliminate the need for fresh first solvent in the first solventextraction stage. In other words, rather than using first solventobtained from a third party to carry out the first solvent extractionstage, the light hydrocarbon liquid distillate may supplement therecycled first solvent to whatever extent necessary in order to providea sufficient amount of first solvent for solvent extracting bitumen fromadditional quantities of material comprising bitumen.

In some embodiments, the method may include extracting bitumen from abitumen comprising material, deasphalting the extracted bitumen toproduce asphaltenes, cracking the asphaltenes inside a nozzle reactor toform light hydrocarbon distillate, and using the light hydrocarbondistillate to extract bitumen from further material comprising bitumen.

As shown in FIG. 3, the method can generally include a first step 300 ofmixing a first quantity of material comprising bitumen with a firstsolvent to form a first mixture, a step 310 of separating the firstmixture into a bitumen-enriched solvent phase and a first solvent-wettailings, a step 320 of separating the bitumen-enriched solvent phaseinto a first bitumen component and a first solvent stream, a step 330 ofdeasphalting the first bitumen component to form an asphaltene streamand a first hydrocarbon stream, a step 340 of cracking the asphaltenestream inside a first nozzle reactor to form a light hydrocarbondistillate and a non-participating hydrocarbon stream, and a step 350 ofmixing the light hydrocarbon distillate with a second quantity ofmaterial comprising bitumen.

First steps 300 and 310 may be essentially identical to steps 100 and110 described in greater detail above. A first solvent as describedabove may be mixed with a material comprising bitumen as described aboveto dissolve the bitumen in the material comprising bitumen. A firstmixture formed by mixing the first solvent and the material comprisingbitumen may be separated into a bitumen-enriched solvent phase asdescribed above and a first solvent-wet tailings as described above.Steps 300 and 310 may be repeated one or more times to extractadditional bitumen from the first solvent-wet tailings.

In step 320, the bitumen-enriched solvent phase can be separated into abitumen component and a first solvent stream. Various manners ofseparating the first solvent from the bitumen may be used. In certainembodiments, 90% or more of the first solvent in the bitumen-enrichedfirst solvent phase may be separated from the bitumen-enriched solventphase to produce a bitumen component.

Separation of the bitumen and the first solvent may be by any suitableseparation method that is capable of separating the first solvent fromthe bitumen component. In certain embodiments, separation may beachieved by heating the bitumen-enriched solvent phase and separatingfirst solvent from bitumen based on the boiling point temperature of thefirst solvent. The heat can be provided by any suitable heating source,such as by a heat exchanger. Heating can be done substantially atambient pressure, at a pressure less than ambient, or at a pressuregreater than ambient. In certain embodiments, the separation of thefirst solvent and the bitumen may be accomplished by a distillationtower.

In some embodiments, separation may be accomplished by utilizing amulti-hearth solvent recovery furnace. Multi-hearth solvent recoveryfurnaces typically include alternating arrangements of centrally locatedhearths and peripherally located hearths. The hearths can be heated, forexample, with oil fired muffles and/or high pressure steam coils. Insome embodiments, hearths near the top of the furnace are heated tohigher temperatures than hearths closer to the bottom of the furnace.

In certain embodiments, the bitumen-enriched solvent phase may be routedto a separator to recover the first solvent. The separator may separatethe first solvent from bitumen product. The separator may also beconfigured to separate any water and mineral solids that might bepresent in bitumen-enriched solvent phase. Separation of thebitumen-enriched solvent phase may also be configured to functiondespite the presence of fine solid material. For example, a separatorused to separate the first solvent from the bitumen can include asuitable packing material, such as vertical slats, to provide increasedsurface area for condensation and evaporation. This packing material canbe resistant to clogging by the fine solid material. In thoseembodiments where the separation is accomplished by utilizing adistillation tower, the fine solid materials may fall to the bottom andbe cleaned out periodically.

The cut temperature of the separator may affect the amount of new firstsolvent present in the separated first solvent. For example, at a cuttemperature of 225° C., an additional 4.8 vol % of first solvent may bepresent in the separated first solvent as new solvent. This additionalfirst solvent may be blended back with the bitumen product produced bythe separator in order to lower the viscosity and make the bitumenproduct more pipelineable.

As described above, first solvent removed from the bitumen-enrichedsolvent phase may be recycled for further use in the same process orcollected for use in other processes. When recycled for use in the sameprocess, the first solvent may be transported back to, for example, afirst vessel used to mix the material comprising bitumen and the firstsolvent. The recovered first solvent may be used to supplement oreliminate a fresh feed of first solvent. The recovered first solvent mayalso be used to supplement first light hydrocarbon distillate producedin the nozzle reactor and recycled back to the first solvent extractionstep.

In step 330, the bitumen obtained from separating the bitumen-enrichedfirst solvent phase as described above can be deasphalted to produce anasphaltene stream. Deasphalting may be accomplished by any suitablemanner for deasphalting bitumen. Examples of suitable deasphaltingprocesses include, but are not limited to, the Residuum OilSupercritical Extraction (ROSE™) process, ambient pressure solventdeasphalting (SDA), and propane deasphalting (PDA).

The type and amount of asphaltene produced by the deasphalting step maydepend on both the solvent used to perform the deasphalting process andthe source of the bitumen material be deasphalted. Bitumen generallyincludes multiple types of asphaltene. Each type of asphaltene may beclassified by the alkane solvent in which the asphaltene is insoluble.For example, a bitumen sample may include a propane-insoluble asphaltenefraction, a butane-insoluble asphaltene fraction, a pentane-insolubleasphaltene fraction, and so on. Table 4 below presents the asphaltenecontent of Athabasca bitumen based on various alkane solvents used toprecipitate the asphaltene.

TABLE 4 Asphaltene Precipitated Solvent from Athabasca Bitumen (wt %)Propane 48 Butane 28 Pentane 18 Hexane 14 Heptane 11 Octane 9.8 Nonane9.4 Decane 9.0

However, it should be noted that while Table 4 indicates that thepentane-insoluble asphaltene content of Athabasca bitumen is 18 wt %,the amount of pentane-insoluble asphaltene content of bitumen may rangefrom about 10 wt % to about 50 wt % of the bitumen based on the sourceof bitumen. Once a solvent has been selected for precipitating aparticular asphaltene fraction, the deasphalting step may generallyrecover from about 25% to 100% of the content of that asphaltenefraction in the bitumen component.

Deasphalting may produce an asphaltene product and a hydrocarbon productthat includes primarily the remaining hydrocarbon fractions of thebitumen. The remaining hydrocarbons may generally include hydrocarbonshaving a molecular weight less than about 300 Daltons. The hydrocarbonsmay also be essentially asphaltene-free In many cases, certain fractionsof the remaining hydrocarbons may be processed further by refineryprocessing to produce various commercial products, such as gasoline,naptha, kerosene and diesel oil.

In step 330, the asphaltene stream produced from the deasphalting step320 may be used to form a light hydrocarbon liquid distillate bycracking the asphaltene stream inside a nozzle reactor. In this regard,step 330 may be similar or identical to step 120 described in greaterdetail above. The nozzle reactor may be similar or identical to thenozzle reactor described above. A cracking material may be injected intoan interior reactor chamber while simultaneously injecting theasphaltene stream into the interior reactor chamber via the materialfeed passage. The asphaltene stream may enter the interior reactorchamber at a direction transverse to the direction the cracking materialis injected into the interior reactor chamber. Shock waves produced bythe cracking material may result in the cracking of the asphaltenematerial into light hydrocarbon liquid distillate having a molecularweight less than 300 Daltons. Asphaltene material not cracked inside thenozzle reactor may be considered non-participating hydrocarbon materialand may be routed to a second nozzle reactor for further cracking.

In certain embodiments, the aspahltene stream injected into the firstnozzle reactor may not be pure asphaltene. Rather, the asphaltene streammay also include resins and other heavy hydrocarbons. When such anasphaltene stream is injected into the nozzle reactor under certainoperating conditions, the asphaltenes may be in a liquid phase while theresins and other heavy hydrocarbons may be in a gaseous state.Accordingly, the resins and hydrocarbons may pass through the nozzlereactor uncracked, while the shock waves produced inside the nozzlereactor will crack the asphaltenes into the light hydrocarbon liquiddistillate. If shock waves miss some of the asphaltenes injected intothe nozzle reactor or only partially crack some of the asphaltenesinjected into the nozzle reactor during the short time that theasphaltenes are inside the nozzle reactor, then these asphaltenes mayalso pass through the nozzle reactor uncracked or not fully cracked andbecome part of the non-participating hydrocarbon stream.

A typical composition of the light hydrocarbon liquid distillateproduced by step 340 is summarized in Table 5.

TABLE 5 Characteristics of Light Hydrocarbon Liquid Distillate InitialBoiling Point 140° C.-160° C. API Gravity 22-30 Kinematic Viscosity 5-7cSt (at 140° F.) Typical Carbon Content 83-84 wt % Typical HydrogenContent 11-12 wt % Typical Sulfur Content 1.5 wt % Micro Carbon Residue~1 wt % Bromine Number 19 Olefin Content 20-24 wt % Sara Analysis -Pentane Solvent Saturates 35 wt % Aromatics 50-60 wt % Resins 10-15 wt %Asphaltenes <1 wt %

Two exemplary components of the light hydrocarbon liquid distillateinclude naphtha and kerosene. Both naphtha and kerosene includearomatics and naphthenes for dissolving bitumen, making the lighthydrocarbon liquid distillates suitable for use as first solvents. Thetable below summarizes key characteristics of the exemplary componentsof the light hydrocarbon liquid distillate. Because both naphtha andkerosene include about 60 wt % solvating components, naphtha andkerosene have about equal solvating (bitumen dissolution) power.

TABLE 5a Solvating Component Content of Light Hydrocarbon LiquidDistillates Naphtha Kerosene Boiling Point Range (° C.) 145-190 190-260Typical Yield from Bitumen 4 wt % 10 wt % Cracking in Nozzle ReactorContent of Solvating Components for Bitumen Dissolution Aromatics 27 wt% 34 wt % Naphthenes 33 wt % 30 wt %

In step 350, the light hydrocarbon liquid distillate produced duringstep 340 may be mixed with a second quantity of material comprisingbitumen. In this regard, step 350 is similar or identical to step 130described in greater detail above. The light hydrocarbon liquiddistillate may act as a suitable solvent for dissolving the bitumencontent of the material comprising bitumen. As such, the lighthydrocarbon distillate may be used in the first mixing step 300described above. In certain embodiments, the light hydrocarbon liquiddistillate may supplement or replace the first solvent used in the firstmixing step.

As with the previous embodiments, the method may include additionalsteps for processing the first solvent-wet tailing phase separated fromthe bitumen-enriched solvent phase in step 310. Processing of the firstsolvent-wet tailings may include a step of mixing the first solvent-wettailings with a second solvent to form a second mixture, separating thesecond mixture into a first solvent-enriched second solvent phase and asecond solvent-wet tailings, and separating the second solvent from thesecond solvent-wet tailings. These steps may be similar or identical tothe steps described above, including the use of a volatile hydrocarbonsolvent as the second solvent, the option of using a plate and framefilter press for the separation step, the option of using acountercurrent washing process to perform the mixing and separationsteps, and the use of a flashing unit or pre-heated gas to separatesecond solvent from the second solvent-wet tailings.

In some embodiments, a system for obtaining light hydrocarbon liquiddistillate from material comprising bitumen includes mixers, separatorsand nozzle reactors. The system may include a first mixer for mixing amaterial comprising bitumen and a first solvent to form a first mixture,a first separator for separating the bitumen-enriched solvent from thefirst mixture, a nozzle reactor for cracking the bitumen component ofthe bitumen enriched solvent phase into a light hydrocarbon liquiddistillate, and a recycle stream for recycling the light hydrocarbondistillate back to the first mixer.

FIG. 4 is a schematic diagram illustrating a system for obtaining lighthydrocarbon distillate from material comprising bitumen. A materialcomprising bitumen 400 and a first solvent 410 may be routed to a firstmixer 420. The material comprising bitumen 400 and first solvent 410 maybe mixed in first mixer 420 as described above in connection with step100. For example, the material comprising bitumen 400 and the firstsolvent 410 may be mixed by the agitation caused by introducing thecomponents into the first mixer 420 or by a powered mixing device.

The material comprising bitumen 400 and the first solvent 410 may be asdescribed above in the method of the previous embodiment. In onespecific example, the material comprising bitumen 400 may be tar sandsand the first solvent 410 may be a light aromatic solvent. The materialcomprising bitumen 400 and the first solvent may be mixed according tothe ratios set forth above in the description of step 100.

Once mixed together, the material comprising bitumen 400 and the firstsolvent 410 form a first mixture 430. The first mixture may be routed toa first separator 440, such as by pumping the first mixture 430 throughpiping fluidly connecting the first mixer 420 and the first separator.In an alternate embodiment, the first mixer 420 and the first separator440 may be the same vessel.

The first separator 440 separates bitumen-enriched solvent phase 450from the first mixture 430. Removal of the bitumen-enriched solventphase 450 results in the first mixture 430 becoming first solvent-wettailings 460, which may be discharged from the first separator 440. Thefirst separator 440 may be any type of separator suitable for separatingthe bitumen-enriched solvent phase 450 from the first mixture 430. Asdiscussed above in greater detail, the bitumen-enriched solvent phase450 may be separated from the first mixture 430 by, for example,settling, filtering or by performing gravity drainage on the firstmixture 430. Accordingly, first separator 440 may be, for example, asettling vessel, a filtration vessel or a gravity drainage vessel. Asalso discussed above, first separator 440 may perform a two stageseparation, with the second stage involving the addition of furtherfirst solvent to the first mixture 430 to displace residualbitumen-enriched solvent phase remaining in the first mixture 430 afterthe first stage of separation.

The bitumen-enriched solvent phase 450 is routed to a nozzle reactor470, such as by pumping the bitumen-enriched solvent phase 450 throughpiping fluidly connecting the first separator 440 and the nozzle reactor470. The bitumen-enriched solvent phase 450 is injected into the nozzlereactor 470 and at least a portion of the bitumen component of thebitumen-enriched solvent phase 450 is cracked into lighter hydrocarbonmaterial.

As discussed in greater detail above, the nozzle reactor 470 can be anynozzle reactor wherein differing types of materials are injected into aninterior reactor chamber of the nozzle reactor 470 and caused tointeract within the interior reactor chamber in order to alter themechanical or chemical composition of one or more of the materials. Incertain embodiments, the nozzle reactor 470 may be a nozzle reactor asdescribed in co-pending U.S. application Ser. No. 11/233,385. In such anozzle reactor, a cracking material 475 is injected into the interiorreaction chamber of the nozzle reactor 470 at an accelerated andpossibly supersonic speed, while the bitumen-enriched solvent phase 450is injected into the interior reaction chamber of the nozzle reactor 470at a direction transverse to the direction that the cracking material475 is injected into the nozzle reactor 470.

The interaction between the bitumen component and the cracking material475 cracks at least a portion of the bitumen component. A portion of thebitumen component that is cracked is cracked into a light hydrocarbonliquid distillate 480 having a molecular weight less than 300 Daltons.Other components of the bitumen-enriched solvent phase 450 may becracked, but not to the molecular weight range for light hydrocarbondistillate 480. Still other components of the bitumen-enriched solventphase 450 may not be cracked inside the nozzle reactor 470 and will exitthe nozzle reactor 470 in the same condition as when it entered thenozzle reactor 470. The uncracked material and the material cracked to amolecular weight outside of the range for light hydrocarbon distillate480 are considered non-participating hydrocarbon. Accordingly, thenozzle reactor 470 may produce a light hydrocarbon distillate stream 480and a combined non-participating hydrocarbon stream 490.

The combined non-participating hydrocarbon stream 490 may includehydrocarbon material that is suitable for use as a commercial product orthat requires further processing to upgrade the hydrocarbon materialinto a useful commercial product. Accordingly, combinednon-participating hydrocarbon stream 490 may be collected forconsumption and/or subjected to further processing to upgrade thehydrocarbon material into useful products. In certain embodiments, thecombined non-participating hydrocarbon stream 490 may be injected into asecond nozzle reactor for further attempts at cracking thenon-participating hydrocarbons.

The light hydrocarbon distillate 480 may be recycled within the systemfor use in mixer 420. That is to say, the light hydrocarbon distillate480 may be mixed with material comprising bitumen 400 in mixer 420 tobegin the process of extracting bitumen from the material comprisingbitumen 400. The light hydrocarbon distillate 480 may supplement firstsolvent 410 to provide a sufficient amount of solvent to mix with thematerial comprising bitumen 400 in the mixer 420, or may replace thefirst solvent 410 such that only light hydrocarbon distillate 480 ismixed with material comprising bitumen 400 in first mixer 420. A lighthydrocarbon distillate bleed stream 485 may also be included in thesystem such that the light hydrocarbon distillate is not constantlyrecycled within the system.

In addition to the light hydrocarbon distillate 480 and combinednon-participating hydrocarbon stream 490, the nozzle reactor 470 mayalso emit cracking material that has not participated in a chemicalreaction with the bitumen-enriched solvent phase 450. The nozzle reactor470 may also emit a small amount of gaseous product produced inside thenozzle reactor, such as hydrogen and methane.

FIG. 5 shows how the system illustrated in FIG. 4 may also includeequipment for processing the first solvent-wet tailings 460. Firstsolvent-wet tailings 460 may be transported to a second separator 500,such as by pumping the first solvent-wet tailings 460 through pipingfluidly connecting the first separator 440 with the second separator500. A second solvent 510 may be added to the first solvent wet tailings460 in the second separator 500, which results in the displacement offirst solvent out of the first solvent-wet tailings 460. Second solvent510 may be added to the first solvent-wet tailings 460 in any amountdescribed above and according to any to procedure described above. Forexample, the second solvent 510 may be added to the first solvent-wettailings 460 in a countercurrent washing process.

The first solvent leaves the second separator 500 as a firstsolvent-second solvent mixture 520. The addition of second solvent 510to the first solvent-wet tailings 460 results in the first solvent-wettailings 460 becoming second solvent-wet tailings 530 due to some of thesecond solvent 510 remaining in the tailings.

The first solvent-second solvent mixture 520 may be sent to a thirdseparator 540, such as by pumping the first solvent-second solventmixture 520 through piping fluidly connecting the second separator 500and the third separation unit 540. The first solvent-second solventmixture 520 is separated into first solvent 550 and second solvent 560.The third separator 540 may be any type of separator suitable forseparating first solvent 550 and second solvent 560, such as a still.The first solvent 550 may then be recycled back in the system for use inthe first mixer 420. The first solvent 550 may supplement or eliminatethe first solvent 410 used to carry out the solvent extraction ofbitumen in mixer 420. In certain embodiments, the first solvent 550 maybe used with the light hydrocarbon distillate 480 to eliminate the needfor first solvent 410. Similarly, the second solvent 560 may be recycledback in the system for use in the second separator 500. The secondsolvent 560 may be used to supplement or eliminate the second solvent510.

The second solvent-wet tailings 530 are transported to a fourthseparator 570, such as by pumping the second solvent-wet tailings 530through piping fluidly connecting second separator 500 and the fourthseparator unit 570. The fourth separator 570 separates the secondsolvent from the second solvent-wet tailings 530. Fourth separator 570may be any suitable type of separator for separating second solvent fromthe second solvent-wet tailings 530, such as a heating or flashing unit.Second solvent stream 580 produced by fourth separator 570 may berecycled back to second separator 500 for use with, or in place of,second solvent 510. Fourth separator 570 also produces a tails stream590 that contains little or no second solvent.

FIG. 6 is a schematic diagram illustrating a system similar to thesystem illustrated in FIG. 4, but including further processing equipmentfor conducting deasphalting on bitumen material. As with FIG. 4, thesystem includes a first mixer 610 for mixing material comprising bitumen600 with first solvent 605 and a first separator 620 for separating abitumen-enriched solvent phase 625 from a first mixture 615 andproducing first solvent-wet tailings 630 by the removal of thebitumen-enriched solvent phase 625 from the first mixture 615.

In the case of the system illustrated in FIG. 6, the bitumen-enrichedsolvent phase 625 undergoes further processing prior to being injectedinto a nozzle reactor 670. Firstly, the bitumen-enriched solvent phase625 is transported to second separator 635 for separating thebitumen-enriched solvent phase 625 into bitumen component 640 and firstsolvent 645. The second separator 635 may be any suitable separator forseparating first solvent 645 from the bitumen component 640, such as aheater that evaporates the first solvent 645 from the bitumen-enrichedsolvent phase 625. The first solvent 645 may be recycled back within thesystem to the first mixer 610, where it may supplement or eliminate thefirst solvent 605.

The bitumen component 640 obtained from the second separation unit 635is transported to a deasphalter 650. The deasphalter 650 may perform anysuitable type of deasphalting step on the bitumen component 640, such asthe ROSE™ process or propane solvent deasphalting process discussedpreviously. Deasphalting unit 650 produces an asphaltene stream 655 anda hydrocarbon stream 660. The hydrocarbon stream 660 may be collected toundergo further processing for the purpose of producing commerciallyuseful product. The asphaltene stream 655 is injected into the nozzlereactor 670.

From this point on, the system shown in FIG. 6 is again similar to thesystem shown in FIG. 4. Cracking material 665 is injected into thenozzle reactor 670 at supersonic speeds to create shockwaves that crackportions of the asphaltene stream 655 injected into the nozzle reactor670. Some of the asphaltene stream 655 will be cracked to produce lighthydrocarbon distillate 680, while the remainder of the asphaltene stream655 will become the non-participating hydrocarbon stream 675. Likehydrocarbon stream 660, the non-participating hydrocarbon stream 675 mayundergo further processing (such as being passed through a second nozzlereactor) to create commercially useful products. Light hydrocarbondistillate 680 may be recycled within the system to be used in the firstsolvent extraction of bitumen from material comprising bitumen 600. Thelight hydrocarbon distillate may be used to supplement the first solvent605 and/or first solvent 645, or may be used eliminate the need forfirst solvent 605 and first solvent 645. A light hydrocarbon distillatebleed stream 685 may also be included in the system such that the lighthydrocarbon distillate is not constantly recycled within the system.

FIG. 7 shows how the system illustrated in FIG. 6 may also includeequipment for processing the first solvent-wet tailings 630. Firstsolvent-wet tailings 630 may be transported to a third separator 700,such as by pumping the first solvent-wet tailings 630 through pipingfluidly connecting the first separator 620 with the third separator 700.A second solvent 705 is added to the first solvent-wet tailings 630loaded in the third separator 700 to displace first solvent from thefirst solvent-wet tailings 630. The second solvent 705 may be any of thesecond solvents described previously and mixing may be carried out asdescribed in greater detail above. The third separator 700 may be anytype of separator, such as a plate and frame-type filter press.

The first solvent-second solvent mixture 710 is transported to a fourthseparator 715, such as by pumping the first solvent-second solventmixture 710 through piping fluidly connecting the third separator 700and the fourth separator 715. The first solvent-second solvent mixture710 is separated into first solvent 720 and second solvent 725. Thefourth separator 715 may be any type of separation unit suitable forseparating first solvent 720 and second solvent 725, such as a still.The first solvent 720 may then be recycled back in the system for use inthe first mixer 610. The first solvent 720 may supplement the firstsolvent 605, first solvent 645 and/or the light hydrocarbon distillate680 used to carry out the solvent extraction of bitumen in mixer 610.Similarly, the second solvent 725 may be recycled back in the system foruse in the second separator 700. The second solvent 725 may be used tosupplement or eliminate the second solvent 705.

The second solvent-wet tailings 730 are transported to a fifth separator735, such as by pumping the second solvent-wet tailings 730 throughpiping fluidly connecting third separator 700 and the fifth separator735. The fifth separator 735 separates the second solvent from thesecond solvent-wet tailings 730. Fifth separator 735 may be any suitabletype of separator for separating second solvent from the secondsolvent-wet tailings 730, such as a heating or flashing unit. Secondsolvent stream 745 produced by fifth separator 735 may be recycled backto third separator 700 for use with, or in place of, second solvent 705and/or second solvent 725. Fifth separator 735 also produces a tailsstream 740 that contains little or no second solvent.

FIG. 8 is a schematic diagram illustrating a system that falls betweenthe systems shown in FIGS. 4 and 6. More specifically, the systemincludes a separator 635 for separating the bitumen-enriched solventphase 625 into bitumen component 640 and first solvent 645, but does notinclude a deasphalter. As such, the bitumen component 640 is injectedinto the nozzle reactor 670 without first undergoing a deasphlatingstep. FIG. 9 shows the system of FIG. 8 together with additional unitsfor processing the first solvent-wet tailings 630.

In view of the many possible embodiments to which the principles of thedisclosed invention may be applied, it should be recognized that theillustrated embodiments are only preferred examples of the invention andshould not be taken as limiting the scope of the invention. Rather, thescope of the invention is defined by the following claims. We thereforeclaim as our invention all that comes within the scope and spirit ofthese claims.

EXAMPLES

The following examples are provided to further illustrate the subjectmatter disclosed herein. These examples should not be considered asbeing limiting in any way.

In the following examples, bitumen was extracted from three differenttar sands—Trinidad tar sands (“Trinidad”), high grade Athabasca tarsands (“AthHG”), and low grade Athabasca tar sands (“AthLG”). Thecomposition of each tar sand material is shown in Table 6 along with abrief description. The composition of each tar sands was determinedusing a Dean-Stark apparatus. Before being used in the examples, the tarsands were broken by hand into pieces small enough to fit through a 0.5inch diameter hole.

The bitumen was extracted from the tar sands using a multi-stageextraction process that included two solvent extraction steps. The tarsands were initially mixed with a liquid solvent (the particular solventis specified in the examples) at atmospheric pressure. The mixture wasseparated into a bitumen-enriched first solvent phase and firstsolvent-wet tailings.

The first solvent-wet tailings were combined with LPG in a pipe. Thepressure in the pipe was sufficient to keep the LPG in a liquid form.This combination was separated into a first solvent-enriched secondsolvent phase and second solvent-wet tailings.

The bitumen-enriched first solvent phase was injected into a nozzlereactor. Steam was also injected into the nozzle reactor in order tocrack at least a portion of the bitumen in the bitumen-enriched firstsolvent phase. The nozzle reactor produced light distillate and anon-participating hydrocarbon stream.

TABLE 6 Tar sands Bitumen Water Sample (wt %) (wt %) DescriptionTrinidad 12 4.6 A blend of drill core samples obtained from a tar sandsin Trinidad. AthHG 12 4 A high grade tar sand sample from the AthabascaTar sands in Alberta, Canada. AthLG 8 5.5 A low grade tar sand samplefrom the Athabasca Tar sands in Alberta, Canada.

Example 1 Trinidad Tar Sands

In this example, bitumen was extracted from a total of eleven samples ofa Trinidad tar sand project. The samples are designated T-1 through T-11in Table 7. The details of the extraction of each sample can be found inTable 7 along with some observations taken during each process.

Except as noted otherwise, each sample was processed using the followingprocedure. Each sample was initially weighed and the sample was placedinto a mixing container along with the necessary amount of the firstsolvent to achieve the proper solvent to bitumen ratio specified inTable 7. The first solvent and the tar sands were mixed with a standardthree blade impeller. The tar sands were leached for one hour in themixing container. The mixture was then filtered with a Buchner funnelwith filter paper, either with gravity or under vacuum or underatmospheric pressure, to separate the liquids from the solids. Thefiltrate of liquids formed a bitumen-enriched solvent phase and thefilter cake of solids formed first solvent-wet tailings.

The first solvent-wet filtrate was weighed and measured. The firstsolvent-wet filter cake was subjected to addition of a second solvent toremove any remnants of the first solvent in the filter cake. The amountof the first solvent still present in the first solvent-wet filter cakevaried depending on the filtration time and the particular solvent used.

The addition of the second solvent was performed by placing the firstsolvent-wet filter cake into a pipe extractor and introducing liquid LPGinto the pipe extractor (commercial LPG was used). The liquid LPGdisplaced any remaining amounts of the first solvent from the firstsolvent-wet filter cake. The first solvent-wet filter cake was soaked inthe liquid LPG for fifteen minutes. The liquids and solids in themixture were separated into a first solvent-second solvent mixture andsecond-solvent wet tailings, respectively. The first solvent-secondsolvent mixture included liquid LPG, bitumen, and first solvent. The LPGwas removed from the bitumen and first solvent by allowing it tovaporize within the system. The bitumen and the first solvent (both inthe form of a liquid) were then captured in a flask. The weight andamount of the liquids were measured. The remaining solids in the pipewere also removed and weighed.

Some of the samples were extracted using the same procedure describedabove with some subtle differences. Sample T-3 was mixed with the firstsolvent in the mixing pipe followed directly by the LPG soaking. SamplesT-6 and T-7 were the same except that the filter cake from T-6 wascompletely dry when placed in the pipe extractor and the filter cakefrom T-7 was still wet when placed in the pipe. Sample T-9 was extractedusing a three step process that included initially extracting bitumenwith liquid LPG in the pipe, separating the liquids and the solids,leaching the solids with the first solvent in the mixing container,separating the liquids and the solids, and extracting the bitumen andany remaining amounts of the first solvent in the pipe extractor withLPG.

The results of the extraction process are shown in Table 8Table. Thetotal weight loss is the difference between the weight of the tar sandsfeedstock and the weight of the second solvent-wet tailings componentremoved from the pipe extractor. The American Petroleum Institute (API)gravity was determined for the liquid extracted from the pipe extractor.The second solvent-wet tailings removed from the pipe extractor wereanalyzed using the Dean-Stark apparatus to determine the amount ofbitumen in the second solvent-wet tailings.

The amount of bitumen in the tar sands feedstock can be calculated usingthis equation: bitumen in tar sands feedstock (wt %)=total weight loss(wt %)−water in tar sands feedstock (wt %)+(100−total weight loss (wt%))*fraction of bitumen in second solvent-wet tailings. Using sample T-1as an example, the calculation was as follows: Bitumen in tar sandsfeedstock (wt %)=18.13−4.6+(100−18.13)*0.0205. The percent of thebitumen that was extracted can then be calculated using this equation:(bitumen in tar sands feedstock (wt %)−(100−total weight loss (wt%))*fraction of bitumen in second solvent-wet tailings)/bitumen in tarsands feedstock (wt %). Using sample T-1 as an example, the calculationwas as follows: (15.20−(100−18.13)*0.0205)/15.20.

TABLE 7 Trinidad Extraction Process Parameters Description First S:BFirst Second Sample Solvent Ratio Extraction Extraction T-1 Biodiesel14:1 1 hour filtration T-2 Toluene  5:1 4-5 hour filtration Filter cakesolids compacted in pipe T-3 Toluene 20:1 Toluene flow slow out of pipe,very compact cake T-4 Xylene 10:1 Filtered overnight Solids poured outeasily T-5 Toluene 10:1 3-5 minute filtration No liquid from pipe T-6Light 10:1 3-5 minute filtration, Sands easily removed, high Distillate*dry filter cake viscosity liquid recovered T-7 Light 10:1 20 minutefiltration, Sands easily removed low Distillate* wet filter cakeviscosity liquid recovered T-8 Light  5:1 3-5 minute filtration, Sandsremoved as one big Distillate* wet filter cake clump, low viscosityliquid recovered T-9 Light 10:1 First extraction: LPG resulted incompacted cake Distillate* Second extraction: filtered first solvent forone hour Third extraction: sands removed easily, low viscosity liquidT-10 Naphtha 10:1 3-5 minute filtration, Solids removed very easily dryfilter cake T-11 Naphtha  5:1 3-5 minute filtration, Solids removed veryeasily dry filter cake *Light distillate solvent used has an API gravityof approximately 30. The light distillate includes highly aromaticcompounds such as toluene, xylene, some benzene, and other ringcompounds. The light distillate was obtained by steam cracking bitumenas described in U.S. Patent Application Publication No. 2006/0144760.

TABLE 8 Trinidad Extraction Results Bitumen in API Gravity Bitumen inSecond Tar Sands Total Bitumen Weight of Extracted Solvent-Wet FeedstockExtracted Sample Loss (%) Liquid Tailings (wt %) (wt %) (wt %) T-1 18.121.0 2.1 15.2 88.9 T-2 17.6 — — — — T-3 18.1 23.1 — — — T-4 17.5 — — — —T-5 18.0 — — — — T-6 14.1 9.2 2.6 11.7 81.3 T-7 14.7 9.8 3.3 12.9 78.3T-8 15.3 21.5 3.3 13.4 79.2 T-9 18.4 28.5 4.8 17.7 78.0 T-10 14.7 — — —— T-11 17.2 — 1.7 13.9 90.2

The bitumen-enriched solvent phase obtained from sample T-8 waspreheated to a temperature of 400° C. using a sand bath heater. Thebitumen-enriched solvent phase was then injected into a nozzle reactorof the type described in U.S. Patent Application Publication No.2006/0144760. The bitumen-enriched solvent phase was injected into thenozzle reactor via the material feed port of the nozzle reactor. Steamat a pressure of 20 bar was also injected into the nozzle reactor via ainjection passage positioned transverse to the material feed passage.Steam and bitumen-enriched solvent phase were injected into the nozzlereactor at a steam:bitumen-enriched solvent phase at a ratio of 2:1. Thepressure inside of the nozzle reactor at injection was 1.5 bar. Thedimensions of the nozzle are set forth in Table 9. The injectedbitumen-enriched solvent phase remained in the nozzle reactor for aperiod of about 1 second.

TABLE 9 Nozzle Reactor Component (mm) Injection Passage, Enlarged Volume148 Injection Section Diameter Injection Passage, Reduced Volume 50Mid-Section Diameter Injection Passage, Enlarged Volume 105 EjectionSection Diameter Injection Passage Length 600 Interior Reactor Chamber187 Injection End Diameter Interior Reactor Chamber 1,231 Ejection EndDiameter Interior Reactor Chamber Length 6,400 Overall Nozzle ReactorLength 7,000 Overall Nozzle Reactor Outside 1,300 Diameter

A liquid product exiting the nozzle reactor was collected and analyzed.The product was separated into a non-participating hydrocarbon streamand a participating hydrocarbon stream. The participating hydrocarbonstream had an API gravity in the range of from 28-35. The participatinghydrocarbon stream contained a mixture of cracked hydrocarbons. Themixture included highly aromatic compounds such as toluene, xylene, somebenzene, and other ring compounds. The molecular weight of the compoundsin the participating hydrocarbon stream generally were less than 300Daltons. The participating hydrocarbon stream was classified as a lightdistillate of the type usable as a first solvent in a solvent extractionstep of the method described above.

Example 2 AthHG Tar Sands

In this example, Bitumen was extracted from a total of four samples ofhigh grade Athabasca tar sands. The samples are designated AHG-1 throughAHG-4 in Table 10. The details of the extraction of each sample can befound in Table 10 along with some observations taken during eachprocess.

The same general procedure outlined in Example 1 was used to extractbitumen from the high grade Athabasca tar sands samples with a few minorexceptions. Some of the samples were mixed with a bowtie shaped coilimpeller instead of the three blade impeller. The coil impeller was usedto ensure adequate mixing and dispersion of the large pieces of clay inthe samples. The samples mixed with the coil impeller are noted in Table10.

In general, it was more difficult to quickly and efficiently filter thehigh grade Athabasca tar sands than the Trinidad tar sands. For example,Sample AHG-1 did filter, but it was left overnight and there was noloose liquid remaining with the filter cake by morning. Also, SampleAHG-2 used the coil impeller which helped it to filter steadily but itwas still somewhat slow. Sample AHG-4 was similar to Samples AHG-1 andAHG-3 except there was no loose liquid with the filter cake when it wasplaced in the pipe extractor. The results of the extraction process areshown in Table 11. It should be noted that Table 11 also shows the APIgravity of the liquid filtrate resulting from the first extractionprocess.

TABLE 10 AthHG Extraction Process Parameters Description First S:B FirstSecond Sample Solvent Ratio Extraction Extraction AHG-1 Light 5:1Filtered Solids removed Distillate overnight, moist easily filter cakeAHG-2 Biodiesel 5:1 Mixed with coil Solids were impeller, two slightlypacked hour atm filter* AHG-3 Light 5:1 Mixed with coil Liquid removedDistillate impeller, atm during N2 purge filtered overnight*, very moistfilter cake AHG-4 Light 5:1 Filters slow Solids were Distillate quitedark *Filtered using Buchner filter with paper at atmospheric pressure(i.e., no vacuum).

TABLE 11 AthHG Extraction Results API API Gravity Bitumen in Bitumen inTotal Bitumen Weight Gravity of Extracted Residual Tar FeedstockExtracted Sample Loss (%) of Filtrate Liquid Sands (wt %) (wt %) (wt %)AHG-1 17.3 28.4 39.5 1.9 16.7 90.7 AHG-2 19.6 28.5 29.6 1.7 17.0 91.7AHG-3 16.9 29.8 26.5 2.3 14.9 87.1 AHG-4 17.0 31.5 29.9 2.4 14.9 86.7

The bitumen-enriched solvent phase obtained from sample AHG-1 waspreheated to a temperature of 400° C. using a sand bath heater. Thebitumen-enriched solvent phase was then injected into a nozzle reactorof the type described in U.S. Patent Application Publication No.2006/0144760. The bitumen-enriched solvent phase was injected into thenozzle reactor via the material feed port of the nozzle reactor. Steamat a pressure of 20 bar was also injected into the nozzle reactor via aninjection passage positioned transverse to the material feed passage.Steam and bitumen-enriched solvent phase were injected into the nozzlereactor at a steam:bitumen-enriched solvent phase at a ratio of 2:1. Thepressure inside of the nozzle reactor at injection was 1.5 bar. Thedimensions of the nozzle are set forth in Table 9 above. The injectedbitumen-enriched solvent phase remained in the nozzle reactor for aperiod of about 1 second.

A liquid product exiting the nozzle reactor was collected and analyzed.The product was separated into a non-participating hydrocarbon streamand a participating hydrocarbon stream. The participating hydrocarbonstream had an API gravity of approximately 28. The participatinghydrocarbon stream contained a mixture of cracked hydrocarbons. Themixture included highly aromatic compounds such as toluene, xylene, somebenzene, and other ring compounds. The molecular weight of the compoundsin the participating hydrocarbon stream generally were less than 300Daltons. The participating hydrocarbon stream was classified as a lightdistillate of the type usable as a first solvent in a solvent extractionstep of the method described above.

Example 3 AthLG Tar Sands

In this example, Bitumen was extracted from a total of four samples oflow grade Athabasca tar sands. The samples are designated ALG-1 throughALG-8 in Table 12. The details of the extraction of each sample can befound in Table 12 along with some observations taken during eachprocess.

The same general procedure outlined in Example 1 was used to extractbitumen from the low grade Athabasca tar sands samples with a few minorexceptions. Sample ALG-4 did not undergo the first extraction processand instead was put directly into the pipe extractor. No liquid wasrecovered from the second extraction process (LPG extraction process)for Sample ALG-2. Sample ALG-3 used biodiesel as the first solvent andwas able to filter fast. A coil impeller was used to mix the firstsolvent and the tar sands. The mixture was subjected to a thirty minutevacuum filtration and thirty minute atmospheric filtration. The filtercake was allowed to air dry under room temperature overnight beforeentering the pipe extractor. The solids were removed from the pipeextractor quite easily. The low grade Athabasca tar sands was easilyprocessed though the system. The results of the extraction process areshown in Table 13.

TABLE 12 AthLG Extraction Process Parameters Description First FirstSecond Sample Solvent Ratio Extraction Extraction ALG-1 Light 6:1Filters very fast Solids removed Distillate easily, light liquid ALG-2Naphtha 6:1 Filtered instantly Solids removed easily, no liquid captureALG-3 Biodiesel 6:1 Filtered fast Few chunks of dark solids ALG-4 —20:1  — Solids were tightly packed in the pipe, minimal liquid recoveredALG-5 Light 5:1 Filtered instantly, Solids removed Distillate heavyfilter cake easily ALG-6 Light 5:1 Filtered instantly, Solids removedDistillate heavy filter cake easily ALG-7 Light 5:1 Dry feed, filteredLots of liquid Distillate for 2 days but still recovered moist, verycompact dark filter cake ALG-8 Light 5:1 Filtered fast Solids were veryDistillate dry, no large clumps of asphaltenes, few pellets of clay

TABLE 13 AthLG Extraction Results API API Gravity Bitumen in Bitumen inTotal Bitumen Weight Gravity of Extracted Residual Tar FeedstockExtracted Sample Loss (%) of Filtrate Liquid Sands (wt %) (wt %) (wt %)ALG-1 13.7 31.6 42.1 1.4 8.4 85.9 ALG-2 15.2 54.5 — — — — ALG-3 16.548.1 13.9 — — — ALG-4 10.8 — 13.9 8.0 11.4 37.8 ALG-5 11.0 32.1 38.3 3.27.4 61.3 ALG-6 13.1 29.2 29.1 2.7 8.9 73.9 ALG-7 6.2 27.4 26.9 6.0 11.249.8 ALG-8 10.0 27.8 31.5 2.1 69.3 64.2The bitumen-enriched solvent phase obtained from sample ALG-1 waspreheated to a temperature of 400° C. using a sand bath heater. Thebitumen-enriched solvent phase was then injected into a nozzle reactorof the type described in U.S. Patent Application Publication No.2006/0144760. The bitumen-enriched solvent phase was injected into thenozzle reactor via the material feed port of the nozzle reactor. Steamat a pressure of 20 bar was also injected into the nozzle reactor via aninjection passage positioned transverse to the material feed passage.Steam and bitumen-enriched solvent phase were injected into the nozzlereactor at a steam:bitumen-enriched solvent phase at a ratio of 2:1. Thepressure inside of the nozzle reactor at injection was 1.5 bar. Thedimensions of the nozzle are set forth in Table 9 above. The injectedbitumen-enriched solvent phase remained in the nozzle reactor for aperiod of about 1 second.

A liquid product exiting the nozzle reactor was collected and analyzed.The product was separated into a non-participating hydrocarbon streamand a participating hydrocarbon stream. The participating hydrocarbonstream had an API gravity of approximately 28. The participatinghydrocarbon stream contained a mixture of cracked hydrocarbons. Themixture included highly aromatic compounds such as toluene, xylene, somebenzene, and other ring compounds. The molecular weight of the compoundsin the participating hydrocarbon stream generally were less than 300Daltons. The participating hydrocarbon stream was classified as a lightdistillate of the type usable as a first solvent in a solvent extractionstep of the method described above.

As used herein, spatial or directional terms, such as “left,” “right,”“front,” “back,” and the like, relate to the subject matter as it isshown in the drawing Figures. However, it is to be understood that thesubject matter described herein may assume various alternativeorientations and, accordingly, such terms are not to be considered aslimiting. Furthermore, as used herein (i.e., in the claims and thespecification), articles such as “the,” “a,” and “an” can connote thesingular or plural. Also, as used herein, the word “or” when usedwithout a preceding “either” (or other similar language indicating that“or” is unequivocally meant to be exclusive—e.g., only one of x or y,etc.) shall be interpreted to be inclusive (e.g., “x or y” means one orboth x or y). Likewise, as used herein, the term “and/or” shall also beinterpreted to be inclusive (e.g., “x and/or y” means one or both x ory). In situations where “and/or” or “or” are used as a conjunction for agroup of three or more items, the group should be interpreted to includeone item alone, all of the items together, or any combination or numberof the items. Moreover, terms used in the specification and claims suchas have, having, include, and including should be construed to besynonymous with the terms comprise and comprising.

Unless otherwise indicated, all numbers or expressions, such as thoseexpressing dimensions, physical characteristics, etc., used in thespecification (other than the claims) are understood as modified in allinstances by the term “approximately.” At the very least, and not as anattempt to limit the application of the doctrine of equivalents to theclaims, each numerical parameter recited in the specification or claimswhich is modified by the term “approximately” should at least beconstrued in light of the number of recited significant digits and byapplying ordinary rounding techniques.

In addition, all ranges disclosed herein are to be understood toencompass and provide support for claims that recite any and allsubranges or any and all individual values subsumed therein. Forexample, a stated range of 1 to 10 should be considered to include andprovide support for claims that recite any and all subranges orindividual values that are between and/or inclusive of the minimum valueof 1 and the maximum value of 10; that is, all subranges beginning witha minimum value of 1 or more and ending with a maximum value of 10 orless (e.g., 5.5 to 10, 2.34 to 3.56, and so forth) or any values from 1to 10 (e.g., 3, 5.8, 9.9994, and so forth).

1. A method comprising: forming a first mixture by mixing a first quantity of material comprising bitumen with a first solvent, wherein the first mixture comprises a bitumen-enriched solvent phase; separating the bitumen-enriched solvent phase from the first mixture and thereby producing first solvent-wet tailings, wherein the bitumen-enriched solvent phase comprises a bitumen component and the first solvent-wet tailings comprise a first solvent component; forming a light hydrocarbon liquid distillate and a non-participating hydrocarbon stream by cracking bitumen component inside a first nozzle reactor; and mixing the light hydrocarbon liquid distillate with a second quantity of material comprising bitumen.
 2. The method as claimed in claim 1, further comprising: separating the first solvent component from the first solvent-wet tailings by adding a second solvent to the first solvent-wet tailings and thereby producing second solvent-wet tailings, wherein the second solvent-wet tailings comprise a second solvent component; and separating the second solvent component from the second solvent-wet tailings.
 3. The method as recited in claim 1, wherein separating the bitumen-enriched solvent phase from the first mixture comprises: a first stage of separating a first quantity of the bitumen-enriched solvent phase from the first mixture by filtering, settling or draining the bitumen-enriched solvent phase from the first mixture; and a second stage of separating a second quantity of the bitumen-enriched solvent phase from the first mixture by adding a second quantity of first solvent to the first mixture.
 4. The method as recited in claim 3, wherein the second stage of separating a second quantity of the bitumen-enriched solvent phase from the first mixture comprises washing the first mixture with the second quantity of first solvent in a countercurrent process.
 5. The method as recited in claim 2, wherein separating the first solvent component from the first solvent-wet tailings comprises washing the first solvent-wet tailings with the second solvent in a countercurrent process.
 6. The method as recited in claim 2, wherein separating the second solvent from the second solvent-wet tailings comprises flashing the second solvent component from the second solvent-wet tailings.
 7. The method as recited in claim 1, wherein separating the bitumen-enriched solvent phase from the first mixture comprises filtering the first mixture in a plate and frame-type filter press.
 8. The method as recited in claim 2, wherein separating the first solvent component from the first solvent-wet tailings comprises adding the second solvent to the first solvent-wet tailings loaded in a plate and frame-type filter press.
 9. The method as recited in claim 7, wherein filtering the first mixture in a plate and frame-type filter press further comprises adding a gas over the first mixture loaded in the plate and frame-type filter press.
 10. The method as recited in claim 8, wherein gas is added over the first solvent-wet tailings loaded in the plate and frame-type filter press.
 11. The method as claimed in claim 1, further comprising: cracking the non-participating hydrocarbon stream inside a second nozzle reactor.
 12. The method as claimed in claim 1, wherein the material comprising bitumen is tar sands.
 13. The method as claimed in claim 1, wherein the first solvent comprises a light aromatic solvent.
 14. The method as claimed in claim 13, wherein the light aromatic solvent comprises kerosene, diesel, gas oil, naphtha, benzene, toluene, an aromatic alcohol, derivatives thereof, or a combination thereof.
 15. The method as claimed in claim 2, wherein the second solvent comprises a volatile hydrocarbon solvent.
 16. The method as claimed in claim 15, wherein the volatile hydrocarbon solvent comprises a cyclo- or iso-paraffin having between 3 and 9 carbons, derivatives thereof, or combinations thereof.
 17. The method as claimed in claim 2, wherein the second solvent is liquefied petroleum gas.
 18. The method as claimed in claim 1, wherein the first nozzle reactor comprises: a reactor body having an interior reactor chamber with an injection end and an ejection end; an injection passage mounted in the nozzle reactor in material injecting communication with the injection end of the interior reactor chamber, the injection passage having (a) an enlarged volume injection section, an enlarged volume ejection section, and a reduced volume mid-section intermediate the enlarged volume injection section and enlarged volume ejection section, (b) a material injection end, and (c) a material ejection end in injecting communication with the interior reactor chamber; and a material feed passage penetrating the reactor body and being (a) adjacent to the material ejection end of the injection passage and (b) transverse to an injection passage axis extending from the material injection end to the material ejection end in the injection passage.
 19. The method as claimed in claim 1, wherein the light hydrocarbon liquid distillate comprises hydrocarbon having a molecular weight less than 300 Daltons.
 20. The method as claimed in claim 1, wherein cracking bitumen component inside the first nozzle reactor comprises: injecting a stream of cracking material through an injection passage into an interior reactor chamber; and injecting the bitumen component into the interior reactor chamber adjacent to the injection passage and transverse to the stream of cracking material entering the interior reactor chamber from the injection passage.
 21. The method of claim 1, further comprising: separating the bitumen-enriched solvent phase into bitumen component and a first solvent phase prior to cracking the bitumen component inside a first nozzle reactor.
 22. The method of claim 21, wherein separating the bitumen-enriched solvent phase into bitumen component and the first solvent phase comprises heating the bitumen-enriched solvent phase to a temperature above the boiling point temperature of the first solvent.
 23. A method comprising: forming a first mixture by mixing a first quantity of material comprising bitumen with a first solvent, wherein the first mixture comprises a bitumen-enriched solvent phase; separating the bitumen-enriched solvent phase from the first mixture and thereby producing first solvent-wet tailings, wherein the bitumen-enriched solvent phase comprises a bitumen component and a primary first solvent component and the first solvent-wet tailings comprise a secondary first solvent component; separating the primary first solvent from the bitumen-enriched solvent phase to thereby isolate the bitumen component of the bitumen-enriched solvent phase; producing an asphaltene stream by deasphalting bitumen component; forming a light hydrocarbon liquid distillate and a non-participating hydrocarbon stream by cracking the asphaltene stream inside a first nozzle reactor; and mixing the light hydrocarbon liquid distillate with a second quantity of material comprising bitumen.
 24. The method as claimed in claim 23, further comprising: separating the secondary first solvent component from the first solvent-wet tailings by adding a second solvent to the first solvent wet tailings and thereby producing second solvent-wet tailings, wherein the second solvent-wet tailings comprise a second solvent component; and separating the second solvent component from the second solvent-wet tailings.
 25. The method as recited in claim 23, wherein separating the bitumen-enriched solvent phase from the first mixture comprises: a first stage of separating a first quantity of the first bitumen-enriched solvent phase from the first mixture by filtering, settling or draining the bitumen-enriched solvent phase from the first mixture; and a second stage of separating a second quantity of the first bitumen-enriched solvent phase from the first mixture by adding a second quantity of first solvent to the first mixture.
 26. The method as recited in claim 25, wherein the second stage of separating the second quantity of the first bitumen-enriched solvent phase from the first mixture comprises washing the first mixture with the second quantity of first solvent in a countercurrent process.
 27. The method as recited in claim 24, wherein separating the first solvent component from the first solvent-wet tailings comprises washing the first solvent-wet tailings with the second solvent in a countercurrent process.
 28. The method as recited in claim 24, wherein separating the second solvent from the second solvent-wet tailings comprises flashing the second solvent component from the second solvent-wet tailings.
 29. The method as recited in claim 23, wherein separating the bitumen-enriched solvent phase from the first mixture comprises filtering the first mixture in a plate and frame-type filter press.
 30. The method as recited in claim 24, wherein separating the first solvent component from the first solvent-wet tailings comprises adding second solvent to the first solvent-wet tailings loaded in a plate and frame-type filter press.
 31. The method as recited in claim 29, wherein filtering the first mixture in a plate and frame-type filter press further comprises adding a gas over the first mixture loaded in the plate and frame-type filter press.
 32. The method as recited in claim 30, wherein gas is added over the first solvent-wet tailings loaded in the plate and frame-type filter press.
 33. The method as claimed in claim 23, further comprising: cracking the non-participating hydrocarbon inside a second nozzle reactor.
 34. The method as claimed in claim 23, wherein the material comprising bitumen is tar sands.
 35. The method as claimed in claim 23, wherein the first solvent comprises a light aromatic solvent.
 36. The method as claimed in claim 35, wherein the light aromatic solvent comprises kerosene, diesel, gas oil, naphtha, benzene, toluene, an aromatic alcohol, derivatives thereof, or a combination thereof.
 37. The method as claimed in claim 24, wherein the second solvent comprises a volatile hydrocarbon solvent.
 38. The method as claimed in claim 37, wherein the volatile hydrocarbon solvent comprises a cyclo- or iso-paraffin having between 3 and 9 carbons, derivatives thereof, or combinations thereof.
 39. The method as claimed in claim 24, wherein the second solvent is liquefied petroleum gas.
 40. The method as claimed in claim 23, wherein the first nozzle reactor comprises: a reactor body having an interior reactor chamber with an injection end and an ejection end; an injection passage mounted in the nozzle reactor in material injecting communication with the injection end of the interior reactor chamber, the injection passage having (a) an enlarged volume injection section, an enlarged volume ejection section, and a reduced volume mid-section intermediate the enlarged volume injection section and enlarged volume ejection section, (b) a material injection end, and (c) a material ejection end in injecting communication with the interior reactor chamber; a material feed passage penetrating the reactor body and being (a) adjacent to the material ejection end of the injection passage and (b) transverse to a injection passage axis extending from the material injection end to the material ejection end in the injection passage.
 41. The method as claimed in claim 23, wherein the light hydrocarbon liquid distillate comprises hydrocarbon having a molecular weight less than 300 Daltons.
 42. The method as claimed in claim 23, wherein cracking the asphaltene stream inside the first nozzle reactor comprises: injecting a stream of cracking material through a injection passage into an interior reactor chamber; and injecting the asphaltene stream into the interior reactor chamber adjacent to the injection passage and transverse to the stream of cracking material entering the interior reactor chamber from the injection passage.
 43. The method as recited in claim 23, wherein separating the first solvent from the bitumen-enriched solvent phase comprises heating the bitumen-enriched solvent phase to a temperature above the boiling point temperature of the first solvent.
 44. A method comprising: solvent extracting a first quantity of material comprising bitumen with at least one solvent to separate bitumen from the first quantity of material comprising bitumen; cracking the bitumen to form a light hydrocarbon liquid distillate; and solvent extracting a second quantity of material comprising bitumen with the light hydrocarbon distillate to separate bitumen from the second quantity of material comprising bitumen.
 45. A method comprising: mixing a first solvent with a first quantity of material comprising bitumen; separating a bitumen-enriched solvent phase from a first result of mixing the first solvent with the first quantity of material comprising bitumen; feeding the bitumen-enriched solvent phase through a nozzle reactor; and mixing a portion of a second result of feeding the bitumen-enriched solvent phase through a nozzle reactor with a second quantity of material comprising bitumen.
 46. The method as recited in claim 45, wherein separating the bitumen-enriched solvent phase from the first result of mixing the first solvent with the first quantity of material comprising bitumen comprises: filtering, settling or draining a first quantity of bitumen-enriched solvent phase from the first result of mixing the first solvent with the first quantity of material comprising bitumen; displacing a second quantity of bitumen-enriched solvent phase from the first result of mixing the first solvent with the first quantity of material comprising bitumen.
 47. The method as claimed in claim 45, wherein the first solvent comprises a light aromatic solvent.
 48. The method as claimed in claim 45, wherein the portion of the second result comprises light hydrocarbon distillate.
 49. A method comprising: mixing a first quantity of material comprising bitumen with a first solvent; separating a bitumen-enriched solvent phase from a first result of mixing the first solvent with the first quantity of material comprising bitumen; separating a first solvent component from the bitumen-enriched solvent phase; deasphalting a second result of separating the first solvent component from the bitumen-enriched solvent phase; feeding a third result of deasphalting the second result into a nozzle reactor; and mixing a portion of a fourth result of feeding the third result into a nozzle reactor with a second quantity of material comprising bitumen.
 50. The method as claimed in claim 49, wherein the first solvent comprises a light aromatic solvent.
 51. The method as claimed in claim 49, wherein the portion of the fourth result comprises light hydrocarbon distillate.
 52. The method as claimed in claim 1, further comprising: upgrading bitumen component of the bitumen-enriched solvent phase.
 53. The method as claimed in claim 23, further comprising: upgrading bitumen component of the bitumen-enriched solvent phase. 